Grove Crane GMK 4100L-1 Lattice Extension Operating Manual 3302730 - PDF DOWNLOAD

Lattice extension operating manual

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Important note Any type of duplication or excerpt from this document, even in electronic form, is not subject to the revision service of Manitowoc Crane Group Germany GmbH.

© Copyright reserved by

Industriegelände West D-26389 Wilhelmshaven, Germany Tel: [+49] (0)44 21 294-0 Fax: +[49] (0) 44 21 294-301 The passing on or duplication of this document as well as the utilisation and disclosure of its contents is prohibited unless expressly permitted. Infringement will incur liability for compensation. All rights pertaining to registration of patent or utility model are reserved. The original language of this document is German.

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Lattice extension operating manual GMK 4100L-1

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Manitowoc Crane Group Germany GmbH

Auxiliary single-sheave boom top Version 2

Depending on the version, the additional auxiliary single-sheave boom top is supplied in version 2.

Version 2 has an additional connecting point (4) and all pins (1), (2) and (3) have a flat head.

In addition to the information given in the lattice extension operating manual, this additional page describes how to swing using the connecting point (4), which makes swinging easier.

à Swinging from working position to transport position, p. 2 à Swinging from transport position to working position, p. 4

02.03.2020

à Note on the removal from the transport position, p. 6

Additional page GMK4100L-1

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1

Swinging from working position to transport position

G

Risk of accidents due to swinging sections!

Always secure the sections with a guide rope from the ground before establishing or separating connections.

This prevents you from being caught or crushed by sections.

The lifting limit switch is removed.

The lifting limit switch weight is removed or secured on the clamp (3).

The hoist rope must be removed.

• Secure the auxiliary single-sheave boom top with a guide rope.

• Remove the pin (2) from the connecting point (1).

• (A) – Swing the auxiliary single-sheave boom top so that the connecting point (5) is aligned.

• (B) – Insert the pin (2) in the connecting

02.03.2020

point (5) and secure it.

2

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Additional page GMK4100L-1

• (A) – Remove the pin (1) from the connecting point (3).

• (B) – Insert the pin (1) in the connecting point (4) and secure it.

• Remove the pin (3) from the connecting point (6).

• (A) – Swing the auxiliary single-sheave boom top on to the main boom until the connecting point (2) is aligned.

• (B) – Insert the pin (3) in the connecting point (2) and secure it.

02.03.2020

• Remove the guide rope.

Additional page GMK4100L-1

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3

Swinging from transport position to working position

G

Risk of accidents due to swinging sections!

Always secure the sections with a guide rope from the ground before establishing or separating connections.

This prevents you from being caught or crushed by sections.

• Secure the auxiliary single-sheave boom top with a guide rope.

• Remove the pin (3) from the connecting point (2).

• (A) – Swing the auxiliary single-sheave boom top so that the connecting point (6) is aligned.

• (B) – Insert the pin (3) in the connecting

02.03.2020

point (6) and secure it.

4

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Additional page GMK4100L-1

• (A) – Remove the pin (1) from the connecting point (4).

• (B) – Insert the pin (1) in the connecting point (3) and secure it.

• Remove the pin (2) from the connecting point (5).

• (A) – Swing the auxiliary single-sheave boom top so that the connecting point (1) is aligned.

• (B) – Insert the pin (2) in the connecting point (1) and secure it.

02.03.2020

• Remove the guide rope.

Additional page GMK4100L-1

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5

Note on the removal from the transport position

02.03.2020

Before lifting the auxiliary single-sheave boom top from the main boom, you must remove the pin (1) from the connecting point (4) in addition to the information in the supplied lattice extension operating manual.

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Additional page GMK4100L-1

These operating instructions contain the following chapters:

1 About these operating instructions 2 Basic safety instructions 3 Operating elements 5 Swing-away lattice 7 Boom extension 8 Heavy load lattice extension (SLS) 2.0 m (6.6 ft) 9 Auxiliary single-sheave boom top 10 Turning loads over 11 Driving with a rigged crane

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12 Index

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Blank page

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Lattice extension operating manual GMK 4100L-1

1 About these operating instructions

1.1

Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

1

1.2

Terms used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

2

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Lattice extension operating manual GMK 4100L-1

2 Basic safety instructions

2.1

Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -

1

2.2

Safety instructions for working with a lattice extension . . . . . . . . . . . . . . . . . . . 2 -

2

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Lattice extension operating manual GMK 4100L-1

3 3

Operating elements

3.1

On the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8

1

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 Rear connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - . 2 Connection section 1 - section 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - . 2 Middle 1 connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - . 3 Middle 2 connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - . 3 Folded connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - . 4 Front connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - . 4 Angle piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - . 5 In the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

7

3.2.1 3.2.2

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 On the RCL control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

7 8

3.3

Other operating elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

9

3.3.1

Rigging hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -

9

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3.2

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4 4

Swing-away lattice

4.1

Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -

4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 Transport dimensions and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6 Transport condition – removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7 Transport condition – folded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11

4.2

Checklists for rigging work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15

4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6

4.2.10 4.2.11

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15 CHECKLIST: Installing the swing-away lattice – into the working position . . . . 4 - 17 CHECKLIST: Installing the swing-away lattice – into the transport position . . . 4 - 21 CHECKLIST: Removing the swing-away lattice – from the working position . . 4 - 24 CHECKLIST: Removing the swing-away lattice – from the transport position . 4 - 27 CHECKLIST: Rigging the swing-away lattice 1.7 + 14.3 m – in the operating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 30 CHECKLIST: Rigging the swing-away lattice 1.7 + 7.7 m – in the operating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 35 CHECKLIST: Rigging the swing-away lattice 1.7 + 14.3 m – in the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 39 CHECKLIST: Rigging the swing-away lattice 1.7 + 7.7 m – in the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 44 CHECKLIST: Subsequent necessary rigging work . . . . . . . . . . . . . . . . . . . . . . . . 4 - 48 CHECKLIST: Preliminary unrigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 50

4.3

Rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 53

4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.3.8 4.3.9 4.3.10

Securing the swing-away lattice with guide ropes . . . . . . . . . . . . . . . . . . . . . . . 4 - 53 Notes on the position of the telescoping cylinder . . . . . . . . . . . . . . . . . . . . . . . . 4 - 55 Establishing/separating the rear connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 56 Establishing/separating the centre 2 connection. . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 58 Establishing/releasing the front connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 59 Folding the fall-back guard out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 60 Section 1/section 2 – Establishing/separating the right-hand connection . . . . . 4 - 61 Section 1/section 2 – Establishing/separating the left-hand connection . . . . . . 4 - 62 Section 1/section 2 – establishing/separating the folded connection . . . . . . . . . 4 - 64 Establishing/disconnecting the electrical connections between section 1 and section 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 65 Establishing/separating the slewing connection . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 67 Setting the angle - with an auxiliary crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 68 Setting the angle - without an auxiliary crane . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 69 Folding the deflection sheaves out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 75 Establishing/disconnecting the electrical connections . . . . . . . . . . . . . . . . . . . . 4 - 77 Relieving the connecting points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 79

4.2.7 4.2.8 4.2.9

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1

4.3.11 4.3.12 4.3.13 4.3.14 4.3.15 4.3.16

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4.3.17 4.3.18 4.3.19 4.3.20 4.3.21 4.3.22 4.3.23 4.3.24 4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.5 4.5.1 4.5.2 4.5.3 4.5.4

Swinging the swing-away lattice when rigging . . . . . . . . . . . . . . . . . . . . . . . . .

Slewing section 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections on the left/right of the main boom head. . . . . . . . . . . . . . . . . . . .

Attaching/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing/removing the lifting limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing/removing the anemometer and air traffic control light . . . . . . . . . .

Installing/removing the camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main boom operation with a folded swing-away lattice – rigging mode . . . .

4 - 81 4 - 83 4 - 84 4 - 86 4 - 89 4 - 91 4 - 93 4 - 95

Operation with a swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 97 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Derricking the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Telescoping with a rigged swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure if the permissible wind speed is exceeded . . . . . . . . . . . . . . . . . . .

Information on the main boom operation when the swing-away lattice is folded/rigged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instructions for turning loads over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 - 97 4 - 98 4 - 99 4 - 100 4 - 101 4 - 102

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 103 Maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance plan M 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance plan M 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 - 103 4 - 103 4 - 103 4 - 105

Finding and eliminating malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 113

4.6.1

Troubleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 113

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5 5

Boom extension

5.1

Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

1

5.1.1 5.1.2 5.1.3 5.1.4 5.1.5

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Transport dimensions and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

1 2 3 4 4

5.2

Checklists for rigging work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

5

5.2.1 5.2.2 5.2.3

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CHECKLIST: installing the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CHECKLIST: removing the boom extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -

5 6 9

5.3

Description of the rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13

5.3.1 5.3.2 5.3.3

5.3.5 5.3.6

Folding the deflection sheave out/in – section 3 . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13 Installing/removing section 3 on/from the main boom . . . . . . . . . . . . . . . . . . . . 5 - 14 Connecting/disconnecting the electrical connections – section 3/ main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15 Connecting/disconnecting the electrical connections – section 3/ swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17 Installing/removing the swing-away lattice on/from section 3 . . . . . . . . . . . . . . 5 - 19 Attaching/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20

5.4

Operation with boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 23

5.4.1 5.4.2 5.4.3 5.4.4

Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 23 Derricking, telescoping the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 25 Procedure if the permissible wind speed is exceeded . . . . . . . . . . . . . . . . . . . . 5 - 26 Instructions for turning loads over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26

5.5

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 27

5.5.1 5.5.2 5.5.3

Maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 27 Maintenance plan M 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 27 Description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 28

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6 6

Heavy load lattice extension (SLS) 2.0 m

6.1

Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

1

6.1.1 6.1.2 6.1.3 6.1.4 6.1.5

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Transport dimensions and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

1 2 3 4 4

6.2

Checklists for rigging work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -

7

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7 CHECKLIST: SLS 2.0 m installation into the working position . . . . . . . . . . . . . . 6 - 8 CHECKLIST: SLS 2.0 m installation into the transport position . . . . . . . . . . . . . 6 - 11 CHECKLIST: SLS 2.0 m removal from the working position . . . . . . . . . . . . . . . . 6 - 12 CHECKLIST: Removing the SLS 2.0 m – from the transport position . . . . . . . . 6 - 15 CHECKLIST: SLS 2.0 m rigging into the working position . . . . . . . . . . . . . . . . . 6 - 17 CHECKLIST: SLS 2.0 m rigging into the transport position . . . . . . . . . . . . . . . . 6 - 21

6.3

Rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 23

6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8

Installing/removing section 6 on/from the main boom . . . . . . . . . . . . . . . . . . . . 6 - 23 Moving section 6 into the working position/transport position . . . . . . . . . . . . . 6 - 26 Connecting/disconnecting the electrical connections – section 6/ main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 30 Positioning/removing the hoist rope – section 6 . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 31 Possible reeving methods on the heavy load lattice extension . . . . . . . . . . . . . 6 - 32 Installing/removing the lifting limit switch and anemometer . . . . . . . . . . . . . . . 6 - 34 Installing/removing the camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 35 Setting the angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 36

6.4

Operating the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 37

6.4.1 6.4.2 6.4.3 6.4.4

Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 37 Derricking, telescoping the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 39 Procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . . . . . 6 - 39 Instructions for turning loads over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 40

6.5

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 41

6.5.1 6.5.2 6.5.3

Maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 41 Maintenance plan M 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 41 Description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 42

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6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7

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7 7

Auxiliary single-sheave boom top

7.1

Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

1

7.1.1 7.1.2 7.1.3

Identification and slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Transport dimensions and weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

1 2 2

7.2

Rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -

3

Moving the auxiliary single-sheave boom top into the working position . . . . . 7 - 3 Moving the auxiliary single-sheave boom top into the transport position . . . . 7 - 6 Installing/removing a folded up auxiliary single-sheave boom top . . . . . . . . . . 7 - 9 Attaching and removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11 Installing/removing the lifting limit switch and anemometer . . . . . . . . . . . . . . . 7 - 13 Installing/removing the camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 16

7.3

Operation with the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . 7 - 17

7.3.1 7.3.2 7.3.3

Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17 Procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . . . . . 7 - 19 Instructions for turning loads over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19

7.4

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21

7.4.1 7.4.2 7.4.3

Maintenance plan M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21 Maintenance plan M 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21 Description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 22

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7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6

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8 Turning loads over

8.1

Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

2

8.2

Turning a load over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -

3

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8

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9 9

Driving with a rigged crane

9.1

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

1

9.2

Driving distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

2

9.3

Permissible rigging modes and axle loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -

3

Swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 4 Boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 8 Heavy load lattice extension (SLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 12 Auxiliary single-sheave boom top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 14

9.4

Before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15

9.5

While driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15

9.6

After driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15

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9.3.1 9.3.2 9.3.3 9.3.4

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10 Index

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10

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About these operating instructions 1.1 Validity

1

About these operating instructions

1.1

Validity

Validity of these operating instructions

Manitowoc Crane Group Germany GmbH.

This operating manual applies only to lattice extensions supplied by

For the operation of the truck crane with a lattice extension described in these operating instructions, all information in the Betriebsanleitung GMK 4100L-1, supplied by the factory for the lattice extension is also applicable.

Prerequisites for installation and operation

The lattice extensions described in this operating manual may only be operated together with a GROVE truck crane GMK 4100L-1 whose serial number is identical with the serial number marked on the lattice extensions.

References to other operating manuals

Cross references to other operating or maintenance manuals are shown, for instance, in the form: Betriebsanleitung GMK4100L-1.

à

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The subject that is referenced can be found in the index or table of contents of the document to which reference is made.

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1-1

About these operating instructions 1.2 Terms used

Terms used

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1.2

1-2

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About these operating instructions 1.2 Terms used

Swing-away lattice 1 Section 1 2 – Sheave 3 – Clamp for the anemometer, air traffic control light 4 – Clamp for pin 5 – Sockets 6 – Clamp for lifting limit switch 7 Section 2 8 – Deflection sheave 9 – slewing connection 10 – Clamp for pin 11 – Cable for electrical connection 12 – Device for setting the angle 13 – Button unit 14 – Fixed point for the hoist rope 15 – Sheave 16 – Deflection sheave 17 – Connection at rear 18 – Middle 1 connection 19 – Folded connection 20 – Middle 2 connection 21 – Joint in front

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22 – Connection section 1 - section 2

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1-3

About these operating instructions 1.2 Terms used

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Lattice extension operating manual GMK 4100L-1

Basic safety instructions 2.1 Other applicable documents

2

Basic safety instructions In principle, all the basic safety instructions from the Betriebsanleitung GMK 4100L-1 are applicable.

Observe also all safety instructions and warnings on the truck crane!

H 2.1

Information regarding the warnings and symbols used; GMK 4100L-1.

à Betriebsanleitung

Other applicable documents In addition to the information in this operating manual, all the instructions in the following sections of the supplied Betriebsanleitung GMK 4100L-1 are also applicable: – Intended use – Improper use – Organisational measures

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– Personnel qualifications

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2-1

Basic safety instructions 2.2 Safety instructions for working with a lattice extension

2.2

Safety instructions for working with a lattice extension This chapter contains additional safety instructions only for safe use of the lattice extensions described in these operating instructions.

Working at heights

If there is a risk of falling when doing work on the truck crane, suitable equipment must be used to prevent falling (e.g. ladder, lifting platform, auxiliary crane).

The lattice extensions are provided with clamps for positioning a ladder.

Place the ladder between the clamps so it cannot slip off.

If despite using such equipment the risk of falling cannot be minimised you must protect yourself and any assisting personnel by using fall arrest systems.

The points at which the fall arrest system can be attached to on the truck crane are indicated by the symbol shown here.

Slinging

Attach parts only at the designated slinging points. If no attachment points are provided, then note to the centre of gravity specifications In this way you prevent the attached parts slipping off, falling and causing injury during installation or removal.

Safety retainers

Always secure the pins at the connection points and also at the holders using the appropriate locks. This prevents unsecured pins coming loose, falling out and causing injuries.

Rigging mode

For crane operation with the lattice extension folded away, comply with the rigging mode. This will prevent damage to the main or lattice extension, and prevent the lattice extension falling during crane operation.

.

For on-road driving with the lattice extension, comply with the rigging mode. This prevents the permissible vehicle width or height being exceeded.

Lifting loads simultaneously with two cranes is particularly hazardous.

Carry out this type of work with special caution.

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Two cranes

2-2

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Operating elements 3.1 On the lattice extension

3

Operating elements This section describes all the lattice extension operating elements that are not described, or are merely referenced in the Betriebsanleitung GMK 4100L1 supplied.

3.1

On the lattice extension

3.1.1

Overview

1 Rear connection 2 Connection section 1–section 2 3 Middle 1 Connection 4 Folded connection 5 Middle 2 connection 6 Front connection

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7 Angle piece

à p. 3 - 5 à p. 3 - 5 à p. 3 - 6 à p. 3 - 7 à p. 3 - 6 à p. 3 - 7 à p. 3 - 8

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3-1

Operating elements 3.1 On the lattice extension

3.1.2

Rear connection (A) – Connection established The locking bar (1) is pushed in and secured.

The pin (2) is pushed out and secured.

(B) – Connection disconnected The locking bar (1) is pulled out and secured.

The pin (2) is pulled in and secured.

3.1.3

Connection section 1 - section 2

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The connection is established using the pins (1) to (4). The pins are inserted into connecting points or holders, depending on whether section 1 is folded in or folded in front of section 2.

3-2

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Operating elements 3.1 On the lattice extension

3.1.4

Middle 1 connection The swing-away lattice is only set down on this connection

3.1.5

Middle 2 connection (A) – Connection established When section 1 is folded in, the pin (1) is inserted into the connecting points (2).

(B) – Connection disconnected

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When the connection is separated, the pin (1) is inserted into the connecting points (3).

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3-3

Operating elements 3.1 On the lattice extension

3.1.6

Folded connection In the illustrated position of the lever (1), section 1 and section 2 are

3.1.7

(A)

connected.

(B)

not connected.

Front connection (A) – Connection established The pin (1) is inserted in the connecting point (2). The pin is secured.

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(B) – Connection disconnected The pin (1) is inserted in the clamp (3) and secured.

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Operating elements 3.1 On the lattice extension

3.1.8

Angle piece Make sure that the pin (1) is in the corresponding position for the desired angle and is secured.

Bore

0

(2)

20

(3)

40

in the clamp (4)

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Angle (°)

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3-5

Operating elements 3.1 On the lattice extension

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3-6

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Lattice extension operating manual GMK 4100L-1

Operating elements 3.2 In the crane cab

3.2

In the crane cab

3.2.1

Overview

1 On the RCL control unit

à p. 3 - 12

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2 CCS control unit

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3-7

Operating elements 3.2 In the crane cab

3.2.2

On the RCL control unit

Enter rigging mode/telescope status menu

For the Standard slewing range type only.

Boom system entry In input mode – select and confirm the boom system 1 Main boom 2 Lattice extension/boom extension 3 Heavy load lattice extension

Input lattice extension – the length before the angle In input mode – select and confirm length.

Input lattice extension – the length after the angle In input mode – select and confirm length.

Lattice extension input – angle Only for manually inclinable lattice extensions

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In input mode – select and confirm the angle.

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Operating elements 3.3 Other operating elements

3.3

Other operating elements

3.3.1

Rigging hook You can also actuate various control elements on the swing-away lattice using the rigging hook (1).

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The rigging hook is fastened in the holders (2).

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3-9

Operating elements 3.3 Other operating elements

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Lattice extension operating manual GMK 4100L-1

Swing-away lattice 4.1 Operations planning

4

Swing-away lattice

4.1

Operations planning

4.1.1

Assembly

S

Risk of overturning in other combinations!

Assemble the swing-away lattice only in the combinations listed as permissible in the Lifting capacity table. Other combinations are not monitored by the RCL.

Permissible combinations

Combination

Designation

Z + Y 1)

Sections used

A

Swing-away lattice A 9.4 m

1.7 + 7.7 m

2

B

Swing-away lattice B 16.0 m

1.7 + 14.3 m

2+1

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1)

Designation in the lifting capacity table: Z = length before setting the angle Y = length after setting the angle

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4-1

Swing-away lattice 4.1 Operations planning

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4-2

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Swing-away lattice 4.1 Operations planning

4.1.2

G

Identification Risk of accidents when using an incorrect swing-away lattice!

Install only the swing-away lattice that belongs to the truck crane. Other swing-away lattices must not be installed.

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The truck crane and corresponding sections 1 and 2 are labelled with the same serial number (3).

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4-3

Swing-away lattice 4.1 Operations planning

4.1.3

G

Slinging points Risk of accidents if used improperly!

Attach slings to the swing-away lattice only at the designated slinging points. Use only lifting gear and joining elements of sufficient load bearing capacity.

Section 1 The slinging points (1) are marked with stickers (2).

The sticker (3) gives data on the weight and the necessary lifting gear.

A guide rope (4) is fastened behind the head of section 1.

Section 2 and section combinations For section 2 and section combinations, the slinging points and the information on weight and required lifting gear are specified on the stickers (1).

The sticker (1) gives data on the weight and the necessary lifting gear.

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The rope attachment point (2) serves as the slinging point for the guide rope.

4-4

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Swing-away lattice 4.1 Operations planning

Example For the combination section 1 folded onto section 2: The sticker (6) shows: – The weight, – The slinging points 2 and 4, – The manner in which the lifting gear must be attached to the slinging points (7).

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Slinging points 2 and 4 on the swing-away lattice are labelled with stickers having the corresponding numerals.

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4-5

Swing-away lattice 4.1 Operations planning

4.1.4

Transport dimensions and weights

Length x width x height in m

Weight in kg

1

6.60 x 0.48 x 0.72

330

2 1 + 2 (pre-folded) 1 + 2 (folded together)

9.85 x 0.85 x 1.30

940

16.55 x 0.85 x 1.30

1,270

9.85 x 0.95 x 1.30

1,270

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Section

4-6

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Swing-away lattice 4.1 Operations planning

4.1.5

S G G

Transport condition – removed Risk of damage to the lattice extension!

Always secure the lattice extension by tying it down with suitable belts when it is transported on a separate vehicle. This prevents the lattice extension from tipping over and becoming damaged during transportation.

Risk of injury!

Before transport make sure that all pins are secured in the clamps with retaining pins. Secure any pins that are not secure.

This way you prevent the pins from falling down while driving and injuring or even killing other persons.

Risk of injury!

Before transport, ensure that all cables and hoses are securely fastened in the clamps and cannot come loose during driving. Additionally fasten the cables and hoses if necessary.

This way you prevent the cables or hoses from falling down while driving and injuring or even killing other persons.

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s

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4-7

Swing-away lattice 4.1 Operations planning

Swing-away lattice

• Check the transport condition and establish this now, if necessary.

à

p. 5 - 75.

– The deflection sheaves (1) and (6) are folded in; – The electrical connection (2) between section 1 - section 2 is disconnected; p. 5 - 65.

– The connection between section 1 - section 2 at the right (3) is p. 5 - 61. All pins that are not required are secured in established; the clamp (4).

– The folded (5) connection has been established; p. 5 - 64.

– The cables are wound onto the clamp (7) and the plug is inserted into the dummy socket; p. 5 - 77.

– The swing-away lattice must be set down and secured on a suitable support (8).

– All electrical cables are closed with caps.

à

à

à

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à

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Swing-away lattice 4.1 Operations planning

– The pins (1)and swivel pins (3) are plugged into the clamp (2) and are p. 5 - 84. secured;

à

à p. 5 - 68.

s

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– The swing-away lattice is in the 0° position (4);

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4-9

Swing-away lattice 4.1 Operations planning

On the main boom

• Check the transport condition and establish this now, if necessary.

– At the Rear connection, the locking bar (1) is pulled out and secured p. 5 - 56. and the pin (2) protrudes out of the bore;

à – The Middle 2 connection (3) is separated; à p. 5 - 58.

– At the Front connection, the pin (4) is inserted and secured in the holder ( p. 5 - 59) and the fall-back guard (5) is folded out ( p. 5 - 60).

à

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à

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Swing-away lattice 4.1 Operations planning

4.1.6

Transport condition – folded

S H

There is a risk of damage to the lattice extension and the main boom!

Always secure the swing-away lattice for on-road driving before driving the truck crane with a folded swing-away lattice.

Only then is the swing-away lattice secured against slipping.

This prevents the partly fastened swing-away lattice from hitting the main boom or the individual components of the swing-away lattice from hitting each other and becoming damaged.

If the truck crane is equipped with the swing-away lattice 1.7 + 14.3 m , the vehicle is wider than 2.55 m.

Section 1 only

• Check the transport condition and establish this now, if necessary.

– The connection between Section 1 - Section 2 at the right is separated; p. 5 - 61. All pins that are not required are secured in the clamp (1) and (2).

à

– At the Rear connection, the locking bar (4) is pulled out and secured and the pin (3) is pulled in and secured; p. 5 - 56.

à – The Middle 2 connection (5) is established; à p. 5 - 58. Section 1 is 07.11.2018

attached to the main boom.

– At the Front connection, the pin (6) is inserted and secured in the holder p. 5 - 59) and the fall-back guard (7) is folded out ( p. 5 - 60). (

à

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à

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s 4 - 11

Swing-away lattice 4.1 Operations planning

Section 1 and Section 2

• Check the transport condition and establish this now, if necessary.

– The electrical connection (2) between section 1 - section 2 is p. 5 - 65. disconnected;

à

– The connection between section 1 - section 2 at the right (3) is established; p. 5 - 61. All pins that are not required are secured in the clamp (4).

à

– The folded (5) connection has been established;

à p. 5 - 64.

– The deflection sheaves (1) and (6) are folded in and secured; p. 5 - 75.

à

– The cables are wound onto the clamp (7) and the plug is inserted into p. 5 - 77. the dummy socket;

à

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– All electrical cables are closed with caps.

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Swing-away lattice 4.1 Operations planning

– At the Rear connection, the locking bar(2) is pulled out and secured and the pin (1) is pulled in and secured; p. 5 - 56.

à

– The Middle 2 connection (3) is established; attached to the main boom.

à p. 5 - 58. Section 1 is

à p. 5 - 68.

– The Front connection (4) has been established (à p. 5 - 59) and the fall-back guard (5) is folded out (à p. 5 - 60).

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– The swing-away lattice is in the 0° position (6);

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4 - 13

Swing-away lattice 4.1 Operations planning

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Swing-away lattice 4.2 Checklists for rigging work

4.2

Checklists for rigging work

4.2.1

Overview The distinction is made between various different procedures.

– Installation and removal These procedures have to be performed when the lattice extension is being transported separately. The installation and removal of the lattice extension is described.

– Rigging Rigging must be performed when the lattice extension is being transported on the truck crane. The changeover between the transport position and the operating position is described.

The table shows which checklist is applicable to any required rigging work.

Required rigging work – Installing swing-away lattice

Swing-away lattice

– Removing the swingaway lattice

– Rigging the swing-away lattice

checklist

– In working position

CHECKLIST: Installing the swing-away lattice – into the working position, p. 5 - 17

– In transport position

CHECKLIST: Installing the swing-away lattice – into the transport position, p. 5 - 21

– From operating position

CHECKLIST: Removing the swing-away lattice – from the working position, p. 5 - 24

– From transport position

CHECKLIST: Removing the swing-away lattice – from the transport position, p. 5 - 27

– In working position

CHECKLIST: Rigging the swing-away lattice 1.7 + 14.3 m (5.6 + 46.9 ft) – in the operating position, p. 5 - 30 CHECKLIST: Rigging the swing-away lattice 1.7 + 7.7 m (5.6 + 25.3 ft) – in the operating position, p. 5 - 35

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– In transport position

CHECKLIST: Rigging the swing-away lattice 1.7 + 14.3 m (5.6 + 46.9 ft) – in the transport position, p. 5 - 39 CHECKLIST: Rigging the swing-away lattice 1.7 + 7.7 m (5.6 + 25.3 ft) – in the transport position, p. 5 - 44

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Swing-away lattice 4.2 Checklists for rigging work

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4.2.2

CHECKLIST: Installing the swing-away lattice – into the working position

H

This checklist is not equivalent to the complete operating instructions.

There are accompanying operating instructions which are indicated by cross-references.

Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is supported on outriggers and the superstructure is turned to the side or to the rear; Betriebsanleitung GMK4100L-1.

à

– The appropriate counterweight for the crane operation must be rigged; Betriebsanleitung GMK4100L-1.

à

– The main boom must be completely retracted and lowered into horizontal position; Betriebsanleitung GMK4100L-1.

The telescoping cylinder must be locked in telescopic section VI; p. 5 - 55.

The main boom is lowered to the horizontal position; Betriebsanleitung GMK4100L-1.

à

à à

– An auxiliary crane must be available.

2. Check that the swing-away lattice is in the for transport condition; p. 5 - 7.

à

3. Fold out the deflection sheaves on section 2;

à p. 5 - 75.

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Swing-away lattice 4.2 Checklists for rigging work

4. Sling lifting gear to the swing-away lattice sections required for combination A or B and fasten a guide rope.

à Assembly, p. 5 - 1, à Identification, p. 5 - 3, à Transport dimensions and weights, p. 5 - 6, à Slinging points, p. 5 - 4.

5. Lift the required section combination in front of the main boom.

6. Establish the connections on the right and left of the main boom head; p. 5 - 84.

à

7. Establish the electrical connection to the main boom;

à p. 5 - 77.

8. For combination A

à p. 5 - 86.

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– Position the hoist rope;

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– Perform all further rigging work;

à p. 5 - 48.

9. For combinations B – Establish the electrical connection between section 1 and section 2; p. 5 - 65.

à

– Fasten the guide rope to section 1;

à p. 5 - 53.

– Disconnect the Folded connection between section 1 and section 2; p. 5 - 64.

à

– Swing section 1 in front of section 2;

à p. 5 - 83.

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– Establish the section 1–section 2 connection at the left;

à p. 5 - 62.

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Swing-away lattice 4.2 Checklists for rigging work

10. Remove the guide rope.

11. Position the hoist rope;

à p. 5 - 86.

à p. 5 - 48.

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12. Perform all further rigging work;

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Swing-away lattice 4.2 Checklists for rigging work

4.2.3

CHECKLIST: Installing the swing-away lattice – into the transport position

H

This checklist is not equivalent to the complete operating instructions.

There are accompanying operating instructions which are indicated by cross-references.

Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is supported on outriggers and the superstructure is turned to the side or to the rear; Betriebsanleitung GMK4100L-1.

à

– The appropriate counterweight for the crane operation must be Betriebsanleitung GMK4100L-1. rigged;

à

– The main boom is fully retracted and locked.

The telescoping cylinder must be locked in telescopic section VI; p. 5 - 55.

The main boom is lowered to the horizontal position; Betriebsanleitung GMK4100L-1.

à à

– An auxiliary crane must be available.

2. Check the transport condition of the swing-away lattice;

à p. 5 - 7.

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3. Sling lifting gear to the swing-away lattice and fasten a guide rope:

à Identification, p. 5 - 3, à Transport dimensions and weights, p. 5 - 6, à Securing the swing-away lattice with guide ropes, p. 5 - 53.

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4. Lift the swing-away lattice onto the main boom and hold it with the guide rope.

5. Establish the slewing connection;

à p. 5 - 67.

6. Remove the sling gear. Hold the swing-away lattice with a guide rope when doing this.

7. Check that the fall-back guard is folded out. Fold out if necessary; p. 5 - 60.

à

8. Ensure that the centre 2 connection is separated;

à p. 5 - 58.

9. Swing the swing-away lattice onto the main boom until it latches at the rear connection, p. 5 - 56.

Visually check that the connection has latched into place. Repeat the procedure if the connection has not latched into place.

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à

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10. Remove guide rope from the front of the swing-away lattice and attach it to the rear.

11. Disconnect the slewing connection;

à p. 5 - 67.

12. Pull the swing-away lattice outwards using the guide rope at the rear until it rests on the fall-back guard.

13. Establish the front connection;

à p. 5 - 59.

14. Remove the guide rope.

à p. 5 - 11.

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15. Check the transport condition of the swing-away lattice;

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Swing-away lattice 4.2 Checklists for rigging work

4.2.4

CHECKLIST: Removing the swing-away lattice – from the working position

H

This checklist is not equivalent to the complete operating instructions. There are accompanying operating instructions which are indicated by cross-references.

Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is supported on outriggers and the superstructure is turned to the side or to the rear; Betriebsanleitung GMK4100L-1.

– The appropriate counterweight for the crane operation must be rigged; Betriebsanleitung GMK4100L-1.

– The main boom is fully retracted and locked.

– The telescoping cylinder must be locked in telescopic section VI; p. 5 - 55.

– The main boom is lowered to the horizontal position; Betriebsanleitung GMK4100L-1.

– An auxiliary crane must be available.

à

à à à

2. Lower the main boom for unreeving the hook block.

3. Perform preliminary unrigging work;

à Betriebsanleitung GMK4100L-1.

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4. Unreeve the hook block;

à p. 5 - 50.

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Swing-away lattice 4.2 Checklists for rigging work

5. Set 0° angle, if necessary;

à

– With an auxiliary crane; p. 5 - 68, – Without an auxiliary crane; p. 5 - 69.

à

6. For combinations B – Fasten the guide rope to section 1;

à p. 5 - 4.

– Separate the section 1–section 2 connection at the left;

– Swing section 1 to the side of section 2;

à p. 5 - 62.

à p. 5 - 83.

– Establish the Folded connection between section 1 and section 2; p. 5 - 64.

à

– Disconnect the electrical connections between section 1 and section 2; p. 5 - 65.

à

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Swing-away lattice 4.2 Checklists for rigging work

7. Disconnect the electrical connection to the main boom;

à p. 5 - 78.

8. Sling lifting gear to the swing-away lattice and fasten a guide rope.

à Assembly, p. 5 - 1, à Identification, p. 5 - 3, à Transport dimensions and weights, p. 5 - 6, à Slinging points, p. 5 - 4.

9. Separate the connections on the right and left of the main boom head; p. 5 - 84.

à

Also disconnect the slewing connection if necessary;

à p. 5 - 67.

10. Lift the swing-away lattice off the main boom and set it aside.

à Assembly, p. 5 - 1, à Identification, p. 5 - 3, à Transport dimensions and weights, p. 5 - 6, à Slinging points, p. 5 - 4.

11. Fold in the deflection sheaves on section 2;

à p. 5 - 76.

à p. 5 - 7.

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12. Check the transport condition of the swing-away lattice;

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Swing-away lattice 4.2 Checklists for rigging work

4.2.5

CHECKLIST: Removing the swing-away lattice – from the transport position

H

This checklist is not equivalent to the complete operating instructions.

There are accompanying operating instructions which are indicated by cross-references.

Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is on outriggers and the superstructure is turned to the side or to the rear.

– The appropriate counterweight for the crane operation must be rigged; Betriebsanleitung GMK4100L-1.

à

– The main boom must be completely retracted and lowered into horizontal position; Betriebsanleitung GMK4100L-1.

à

– An auxiliary crane must be available.

– The transport condition has been established; folded, p. 5 - 11.

à Transport condition –

2. Sling the swing-away lattice and fasten a guide rope to the rear of section 2.

à Identification, p. 5 - 3, à Transport dimensions and weights, p. 5 - 6, à Securing the swing-away lattice with guide ropes, p. 5 - 53.

3. Separate the Front connection; lattice with the guide rope.

à p. 5 - 59. Hold the swing-away

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4. Pull the swing-away lattice onto the main boom using the guide rope until the slewing connection is aligned.

5. Establish the slewing connection;

à p. 5 - 67.

6. Attach the guide rope to the front of section 2;

7. Disconnect the centre 2 connection;

8. Disconnect the rear connection;

à p. 5 - 58.

à p. 5 - 56.

à p. 5 - 60.

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9. Fold in the fall-back guard;

à p. 5 - 53.

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10. Swing the swing-away lattice with the guide rope outwards; p. 5 - 81.

à

11. Disconnect the slewing connection;

à p. 5 - 67.

12. Lift the swing-away lattice off the main boom and set it aside.

13. Remove the sling gear.

14. Remove the guide rope.

à p. 5 - 7.

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15. Check the transport condition of the swing-away lattice;

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Swing-away lattice 4.2 Checklists for rigging work

4.2.6

CHECKLIST: Rigging the swing-away lattice 1.7 + 14.3 m – in the operating position

H

This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is on outriggers and the superstructure is turned to the side or to the rear.

– The appropriate counterweight for the crane operation must be rigged; Betriebsanleitung GMK4100L-1.

à

– The main boom is fully retracted and locked.

The telescoping cylinder must be locked in telescopic section VI; p. 5 - 55.

The main boom is lowered to the horizontal position; Betriebsanleitung GMK4100L-1.

à à

2. Check the transport condition of the swing-away lattice;

à p. 5 - 53.

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3. Attach the guide rope to the rear of section 2;

à p. 5 - 11.

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4. Separate the Front connection; lattice with the guide rope.

à p. 5 - 59. Hold the swing-away

5. Pull the swing-away lattice onto the main boom using the guide rope until the slewing connections are aligned.

6. Establish the slewing connection;

à p. 5 - 67.

7. Establish the electrical connection to the main boom;

8. Attach the guide rope to the front of section 2;

9. Disconnect the centre 2 connection;

à p. 5 - 77.

à p. 5 - 53.

à p. 5 - 58.

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à

10. Disconnect the rear connection; p. 5 - 56.

Hold the swing-away lattice with the guide rope.

11. Fold in the fall-back guard;

à p. 5 - 60.

12. Swing the swing-away lattice in front of the main boom head; p. 5 - 81.

à

13. Establish the connections on the left and right of the main boom head.

à Connections on the left/right of the main boom head, p. 5 - 84, à Relieving the connecting points, p. 5 - 79,

14. Fasten the guide rope to the head of section 2;

à p. 5 - 64.

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15. Disconnect folded connection;

à p. 5 - 53.

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16. Swing section 1 in front of section 2;

à p. 5 - 83.

17. Establish the section 1–section 2 connection at the left;

à p. 5 - 62.

18. Establish the electrical connection between section 1 and section 2; p. 5 - 65.

à

19. Fold out the deflection sheaves;

20. Position the hoist rope;

à p. 5 - 75.

à p. 5 - 86.

21. Remove the guide rope.

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Swing-away lattice 4.2 Checklists for rigging work

22. Set the angle position if necessary.

à

p. 5 - 68, – With an auxiliary crane; p. 5 - 69.

– Without an auxiliary crane;

à

à p. 5 - 48.

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23. Perform subsequent necessary rigging work;

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4.2.7

CHECKLIST: Rigging the swing-away lattice 1.7 + 7.7 m – in the operating position

H

This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is on outriggers and the superstructure is turned to the side or to the rear.

– The appropriate counterweight for the crane operation must be rigged; Betriebsanleitung GMK4100L-1.

à

– The main boom is fully retracted and locked.

The telescoping cylinder must be locked in telescopic section VI; p. 5 - 55.

The main boom is lowered to the horizontal position; Betriebsanleitung GMK4100L-1.

à à

2. Check the transport condition of the swing-away lattice;

3. Attach the guide rope to the rear of section 2;

à p. 5 - 11.

à p. 5 - 53.

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4. Separate the Front connection; lattice with the guide rope.

à p. 5 - 59. Hold the swing-away

5. Pull the swing-away lattice onto the main boom using the guide rope until the slewing connections are aligned.

6. Establish the slewing connection;

à p. 5 - 67.

7. Establish the electrical connection to the main boom;

8. Fold in the fall-back guard;

à p. 5 - 77.

à p. 5 - 60.

à p. 5 - 53.

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9. Attach the guide rope to the front of section 2;

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10. Ensure that the centre 2 connection is established;

à p. 5 - 58.

11. Check that the electrical connection between section 1 and section 2 has been disconnected; p. 5 - 65.

à

12. Disconnecting connections.

– Separate the section 1–section 2 connection at the right;

– Disconnect folded connection;

à p. 5 - 61.

à p. 5 - 64.

13. Swing the swing-away lattice in front of the main boom head; p. 5 - 81.

à

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14. Establish the connections on the left and right of the main boom head.

à Connections on the left/right of the main boom head, p. 5 - 84, à Relieving the connecting points, p. 5 - 79,

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15. Fold out the deflection sheaves;

16. Position the hoist rope;

à p. 5 - 75.

à p. 5 - 86.

17. heck the transport condition of section 1;

à p. 5 - 11.

18. Remove the guide rope.

19. Set the angle position if necessary.

à

– With an auxiliary crane; p. 5 - 68, – Without an auxiliary crane; p. 5 - 69.

à

à p. 5 - 48.

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20. Perform subsequent necessary rigging work;

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Swing-away lattice 4.2 Checklists for rigging work

4.2.8

CHECKLIST: Rigging the swing-away lattice 1.7 + 14.3 m – in the transport position

H

This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is on outriggers and the superstructure is turned to the side or to the rear.

– The appropriate counterweight for the crane operation must be rigged; Betriebsanleitung GMK4100L-1.

à

– The main boom is fully retracted and locked.

The telescoping cylinder must be locked in telescopic section VI; p. 5 - 55.

à

2. Lower the main boom for unreeving the hook block.

3. Unreeve the hook block;

à Betriebsanleitung GMK4100L-1.

4. Perform preliminary unrigging work;

à p. 5 - 50.

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Swing-away lattice 4.2 Checklists for rigging work

5. Set 0° angle, if necessary;

à

p. 5 - 68, – With an auxiliary crane; p. 5 - 69.

– Without an auxiliary crane;

à

6. Fasten the guide rope to section 1;

à p. 5 - 53.

7. Separate the section 1–section 2 connection at the left;

à p. 5 - 62.

8. Disconnect the electrical connections between section 1 and section 2; p. 5 - 65.

à

9. Swing section 1 onto section 2;

à p. 5 - 64.

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10. Make the Folded connection;

à p. 5 - 83.

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11. Attach a guide rope from section 1 to section 2;

à p. 5 - 53.

12. Disconnect the electrical connection to the main boom;

13. Fold in the deflection sheaves;

à p. 5 - 78.

à p. 5 - 75.

14. Check that the slewing connection has been established and establish this if necessary; p. 5 - 67.

à

15. Fold out the fall-back guard;

à p. 5 - 60.

16. Ensure that the centre 2 connection is separated;

à p. 5 - 58.

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Swing-away lattice 4.2 Checklists for rigging work

17. Separate the connections on the right and left of the main boom head; p. 5 - 84.

à

18. Swing the swing-away lattice onto the main boom until it latches at the rear connection, p. 5 - 56.

Visually check that the connection has latched into place. Repeat the procedure if the connection has not latched into place.

à

19. Remove guide rope from the front of the swing-away lattice and attach it to the rear.

20. Disconnect the slewing connection;

à p. 5 - 67.

21. Pull the swing-away lattice outwards using the guide rope at the rear until it rests on the fall-back guard.

à p. 5 - 59.

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22. Establish the front connection;

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23. Remove the guide rope.

à p. 5 - 11.

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24. Check the transport condition of the swing-away lattice;

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Swing-away lattice 4.2 Checklists for rigging work

4.2.9

CHECKLIST: Rigging the swing-away lattice 1.7 + 7.7 m – in the transport position

H

This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is on outriggers and the superstructure is turned to the side or to the rear.

– The appropriate counterweight for the crane operation must be rigged; Betriebsanleitung GMK4100L-1.

à

– The main boom is fully retracted and locked.

The telescoping cylinder must be locked in telescopic section VI; p. 5 - 55.

The main boom is lowered to the horizontal position; Betriebsanleitung GMK4100L-1.

à à

– Section 1 is fastened to the side of the main boom;

à p. 5 - 4.

2. Lower the main boom for unreeving the hook block.

à Betriebsanleitung GMK4100L-1.

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3. Unreeve the hook block;

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4. Perform preliminary unrigging work;

à p. 5 - 50.

5. Set 0° angle, if necessary;

à

– With an auxiliary crane; p. 5 - 68, p. 5 - 69.

– Without an auxiliary crane;

à

6. Fasten the guide rope to section 2;

7. Fold in the deflection sheaves;

à p. 5 - 53.

à p. 5 - 75.

8. Disconnect the electrical connection to the main boom;

à p. 5 - 78.

9. Check that the slewing connection has been established and establish this if necessary; p. 5 - 67.

à

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Swing-away lattice 4.2 Checklists for rigging work

10. Fold out the fall-back guard;

à p. 5 - 60.

11. Separate the connections on the right and left of the main boom head; p. 5 - 84.

à

12. Swing the swing-away lattice onto the main boom until the section 1– section 2 connection at the right-hand side is aligned; p. 5 - 61.

à

13. Establish the section 1–section 2 connection at the right;

14. Make the Folded connection;

à p. 5 - 61.

à p. 5 - 64.

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15. Remove guide rope from the front of the swing-away lattice and attach it to the rear.

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16. Disconnect the slewing connection;

à p. 5 - 67.

17. Pull the swing-away lattice outwards using the guide rope at the rear until it rests on the fall-back guard.

18. Establish the front connection;

à p. 5 - 59.

19. Remove the guide rope.

à p. 5 - 11.

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20. Check the transport condition of the swing-away lattice;

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Swing-away lattice 4.2 Checklists for rigging work

4.2.10

CHECKLIST: Subsequent necessary rigging work

H

This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions there!

1. Prerequisite – The rigging work specified in the corresponding checklist has been correctly performed.

2. Mount the anemometer and if necessary the air traffic control light; p. 5 - 91.

à

3. If necessary, mount the camera;

à p. 5 - 93.

4. Reeve the hoist rope on the hook block; 4100L-1.

à Betriebsanleitung GMK

5. Install the lifting limit switch, attach the lifting limit switch weight and place it around the hoist rope;

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à p. 5 - 89; à Betriebsanleitung GMK 4100L-1.

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6. If necessary, remove the hand-held control; GMK4100L-1.

à Betriebsanleitung

7. Check the horizontal alignment of the truck crane and correct, if necessary.

8. Enter the current rigging mode with the rigged swing-away lattice; Setting the RCL, p. 5 - 97.

à

9. Enter the current reeving;

à Setting the RCL, p. 5 - 97.

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10. Continue the work specified in the initial checklist.

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Swing-away lattice 4.2 Checklists for rigging work

4.2.11

CHECKLIST: Preliminary unrigging work This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions there!

1. Prerequisite – The rigging work specified in the corresponding checklist has been correctly performed.

2. If necessary, remove the anemometer and air traffic control light; p. 5 - 91.

à

3. Remove the lifting limit switch weight and lifting limit switch;

à Installing/removing the lifting limit switch, p. 5 - 89; à Betriebsanleitung GMK 4100L-1.

4. If necessary, remove the camera;

à p. 5 - 93.

à Betriebsanleitung

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5. If necessary, connect the hand-held control; GMK4100L-1.

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6. Unreeve the hoist rope and remove it from the swing-away lattice; p. 5 - 86.

à

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7. Continue the work specified in the initial checklist.

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Swing-away lattice 4.2 Checklists for rigging work

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Swing-away lattice 4.3 Rigging work

4.3

Rigging work

4.3.1

Securing the swing-away lattice with guide ropes

G

Risk of accidents due to sections swinging of their own accord!

Always fasten a guide rope to the sections being swung before you disconnect or unlock the required connections.

An extra person must keep the guide rope tightly tensioned or you must fasten the guide rope so that the sections cannot slew unintentionally when the necessary connections are unlocked or separated.

Attach the guide rope to the front of section 2

• Fasten the guide rope to the swing-away lattice A or B, for example to the rope attachment point (1).

Attach the guide rope to the rear of section 2

• Attach the guide rope to the swing-away lattice A or B, for example to the left-hand standpipe (1).

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Swing-away lattice 4.3 Rigging work

Fasten a guide rope to section 1

• Fasten the guide rope behind the head of section 1 (1).

(A) – For pivoting onto the main boom

• Attach the guide rope to the rope attachment point (1).

• Guide the rope underneath the swing-away lattice, over the rope guide (2) on the main boom and back again.

(B) – For pivoting in front of the main boom head

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• Attach the guide rope to the strap pipe (1).

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Swing-away lattice 4.3 Rigging work

4.3.2

Notes on the position of the telescoping cylinder The connections (1), (2) and (3) must be aligned when rigging the swing-away lattice.

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The brackets on the main boom are adjusted so that the connections line up only when the main boom is fully telescoped in and all telescopic sections are set down.

After retracting, additionally lock the telescoping cylinder in telescopic sectionVI in order to fix in this position.

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Swing-away lattice 4.3 Rigging work

4.3.3

Establishing/separating the rear connection A spring-loaded pin latches into place when the swing-away lattice is swung in the connection.

To swing out of the connection, the pin is pulled down using the lever to allow the swing-away lattice to be swung.

The pin must be pushed in or pulled out for the two conditions above.

Establishing Prerequisites: – The slewing connection has been made; p. 5 - 67.

à

– A guide rope must be attached

à p. 5 - 53.

You can use the rigging hook for this; p. 3 - 17.

à

Before the swing-away lattice is swung onto the main boom:

• Check that the pin (2) protrudes about 35 mm out of the bore.

If the pin does not protrude out of the bore:

• Pull the locking bar (5) until the pin (2) is pushed up by the spring force.

• Pull out the locking bar (4) and lock it by turning to the right.

• Pull the pin (3) out as far as possible.

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G

Danger of injury to the hands due to the lever moving upwards suddenly!

The lever (1) moves upwards suddenly when you release the locking bar (5). Keep your hands away from the lever (1) if you manually actuate the rear connection. This will prevents you from injuring your hands.

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Swing-away lattice 4.3 Rigging work

• Swing the swing-away lattice into the rear connection until the pin (2) audibly latches into place.

If the pin (2) does not latch into place:

• Pull the swing-away lattice away from the rear connection and then swing it back into the connection again.

• Unlock the locking bar (4) by turning it to the right.

• Push the pin (3) in until the locking bar (4) engages in the pin's bore hole (3).

Disconnecting Prerequisites: – The slewing connection has been made; p. 5 - 67.

à

– A guide rope must be attached

à p. 5 - 53.

You can use the rigging hook for this; p. 3 - 17.

à

• Pull out the locking bar (4) and lock it by turning to the right.

• Pull the pin (3) out as far as possible.

• Unlock the locking bar (4) by turning it to the right.

• Pull the lever down (1) until the locking bar (5) latches into place.

• Swing the swing-away lattice out of the rear connection. Use the guide rope for this.

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Swing-away lattice 4.3 Rigging work

After the swing-away lattice has been swung, the Rear connection must be set for the next rigging into the transport position.

• Hold the swing-away lattice in position using the guide rope.

• Pull the locking bar (1) until the pin (2) is pushed up by the spring force.

The lever (3) then moves up suddenly.

G 4.3.4

Danger of injury to the hands due to the lever moving upwards suddenly!

The lever (3) moves upwards suddenly when you release the locking bar (1). Keep your hands away from the lever (3) if you manually actuate the rear connection. This will prevents you from injuring your hands.

Establishing/separating the centre 2 connection (A) – Establishing the connection The swing-away lattice is folded onto the main boom so that the connecting points on section 1 and the centre 2 connection are aligned.

• Remove the pin (1) from connecting point (3) and insert it into connecting point (2).

• Secure the pin.

(B) – Disconnecting the connection

• Remove the pin (1) from connecting point (2) and insert it into connecting point (3).

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• Secure the pin.

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Swing-away lattice 4.3 Rigging work

4.3.5

Establishing/releasing the front connection

Establishing Prerequisites: – The slewing connection is separated; p. 5 - 67.

– The rear connection has been established; p. 5 - 56.

à à

– The fall-back guard (4) is folded out; p. 5 - 60.

à

• Pull the swing-away lattice by the guide rope until the connecting points (3) are aligned.

• Remove the pin (1) from the clamp (2).

• Fit the pin (1) into the connecting point (3) and secure it.

Disconnecting Prerequisites: – The rear connection has been established; p. 5 - 56.

à

– The fall-back guard (4) is folded out; p. 5 - 60.

à

• Remove the pin (1) from the connecting point (3).

• Plug the pin (1) into the clamp (2) and

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secure it.

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Swing-away lattice 4.3 Rigging work

4.3.6

G

Folding the fall-back guard out/in Risk of accidents due to the fall-back guard not moving freely!

Make sure that the fall-back guard can always move freely. The fall-back guard does not fall into the vertical position if it cannot move freely. The swing-away lattice can then roll off the support.

Prerequisites: When slewing/swinging:

à p. 5 - 56.

– The slewing connection has been made; à p. 5 - 67.

– The rear connection has been established;

Folding out

• Push the locking bar (3) to position A. The fall-back guard (1) falls into the vertical position.

• Check that the fall-back guard (1) is in the vertical position. If it is not in a vertical position then turn it into the vertical position.

Folding in

• Turn the fall-back guard until the locking bar (3) and slot are aligned (2).

• Push the locking bar (3) into the slot (2) (position B).

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The fall-back guard is secured in the horizontal position.

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Swing-away lattice 4.3 Rigging work

4.3.7

Section 1/section 2 – Establishing/separating the right-hand connection

Connecting

• Slew section 1 to section 2 until the connecting points (2) are aligned.

• Remove the pin (1) from the clamp (3).

• Insert the conical pin (1) into the lower connecting point (2) and secure it.

• Insert the pin (1) into the upper connecting point (2) and secure it.

Disconnecting

G

Risk of accidents due to falling parts!

Ensure that all necessary connections have been established as specified in the checklist before separating this connection.

This prevents any swing-away lattice sections from falling down during swinging, or when the main boom is raised later.

• Remove the pins (1) from the connecting points (2) and plug them into the clamps (3).

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• Secure the pins.

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Swing-away lattice 4.3 Rigging work

4.3.8

Section 1/section 2 – Establishing/separating the left-hand connection

Establishing

• Remove the pins (1) from the clamp (3) and plug them into the connecting points (2).

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• Secure the pins.

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Swing-away lattice 4.3 Rigging work

Disconnecting

G G

Risk of accidents through section 1 swinging of its own accord!

Always approach the connecting point from the left side only and position a ladder only to the left of section 2.

This prevents section 1 from swinging of its own accord and crushing you or knocking you off the ladder.

Risk of accidents due to falling section!

Ensure that all necessary connections have been established as specified in the checklist before separating this connection.

This prevents section 1 from falling during slewing.

• Remove the pins (1) from the connecting points (2) and plug them into the clamps (3).

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• Secure the pins.

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Swing-away lattice 4.3 Rigging work

4.3.9

Section 1/section 2 – establishing/separating the folded connection

Establishing

• Remove the pin (1) from the connecting point (2).

• Fold the locking bar (3) until it is aligned with the connecting point (4) on section 1.

• Fit the pin (1) into the connecting point (4) and secure it.

Disconnecting

G

Risk of accidents due to falling parts!

Ensure that all necessary connections have been established as specified in the checklist before separating this connection.

This prevents any swing-away lattice sections from falling down during swinging, or when the main boom is raised later.

• Remove the pin (1) from the connecting point (4).

• Fold the locking bar (3) until it is aligned with the connecting point (2) on section 2.

• Fit the pin (1) into the connecting point (2)

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and secure it.

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Swing-away lattice 4.3 Rigging work

4.3.10

Establishing/disconnecting the electrical connections between section 1 and section 2

Establishing For electrical system

• Unwind the cable (3) from the clamp (4).

• Remove the plug (2) from the dummy socket (5) and plug it into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation and when slewing section 1.

For camera

• Unwind the cable (3) from the clamp (4).

• Insert the plug (2) in the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation and when slewing section 1.

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Swing-away lattice 4.3 Rigging work

Disconnecting For electrical system

• Remove the plug (2) from the socket (1) and plug it into the dummy socket (5).

• Wind the cable (3) on to the holder (4).

• Cover the socket (1) with the cap.

For camera

• Remove the plug (2) from the socket (1).

• Wind the cable (3) on to the holder (4).

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• Cover the plug and socket with caps.

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4.3.11

Establishing/separating the slewing connection

Establishing Prerequisites:

à

– The 0° angle is set; p. 5 - 68.

– A guide rope must be attached to the rear of section 2.

• Pull the swing-away lattice by the guide rope until the connecting points (2) are aligned.

• Remove the pins (1) from the clamp (3) and plug them into the connecting points (2).

• Secure the pins.

Disconnecting

G

Risk of accidents due to the swing-away lattice falling!

Ensure that the swing-away lattice is slung on an auxiliary crane or attached to the main boom before separating the slewing connection. This prevents the swing-away lattice from falling down and injuring or killing you or other persons.

Prerequisites:

à

– The 0° angle is set; p. 5 - 68.

– A guide rope must be attached to the rear of section 2.

• Remove the pins (1) from the connecting points (2) and plug them into the clamps (3).

• Secure the pins.

• Pull the swing-away lattice outwards using

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Swing-away lattice 4.3 Rigging work

4.3.12

G

Setting the angle - with an auxiliary crane Risk of accidents due to swing-away lattice folding down!

Always secure the swing-away lattice with an auxiliary crane, or set it down on the ground, before removing the angling pins from the bores.

In this way, you prevent the swing-away lattice from suddenly unfolding downwards and causing personal injury.

• Lift the swing-away lattice using an auxiliary crane.

• Remove the pin (1) from the bore.

• Insert the pin for the desired angle into the corresponding bore (1).

Angle (°)

Bore

0

(2)

20

(3)

40

in the clamp (4)

• Secure the pin.

• Lower the swing-away lattice down or lift it up.

• Remove the lifting gear.

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If the swing-away lattice now touches the ground at the set angle, then the angle will set itself when the main boom is raised.

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Swing-away lattice 4.3 Rigging work

4.3.13

Setting the angle - without an auxiliary crane If an auxiliary crane is not available, the swing-away lattice must be set down before it is angled.

S Entering the RCL code

Risk of damage to the hoist rope Unreeve the hook block and set down the hoist rope beside the swing-away lattice before you angle the swing-away lattice.

In this way you prevent the hoist rope from being damaged when the head of the swing-away lattice is set down on the ground for angling.

For angling without an auxiliary crane, you must enter the RCL code for working with a mounted lattice extension.

Comply with the information in the section Rigging tables - lattice extension in the lifting capacity tables. Among other information, this specifies the possible telescoping modes and the maximum lifting capacity.

G G

Risk of overturning with impermissible rigging mode!

Always enter the RCL rigging code for the current rigging mode of the truck crane, and only slew the superstructure into the operating position permitted by the RCL rigging code set according to the lifting capacity table.

This prevents the truck crane from overturning when the main boom is telescoped out.

Risk of overturning with raised hook block (hook tackle)!

The telescoping range which is enabled for the RCL code set is only permitted for telescoping without a load and without hook block/hook tackle.

When the main boom is fully extended, load measurement is not possible and the RCL monitoring depends on the working radius only.

For this reason, you must unreeve the hook block. This prevents the truck crane from overturning when the main boom is telescoped out.

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Swing-away lattice 4.3 Rigging work

Adjusting the angle

G G

This section assumes that the swing-away lattice has been locked in front of the main boom and the unreeved hoist rope has been set down beside the swing-away lattice.

Risk of accidents if this procedure is not followed!

For the procedure described here, the swing-away lattice must be set down on the ground. If the swing-away lattice is to be set down on some other structure for inclination, please bear in mind that the swing-away lattice will slide towards the truck crane when raised, until the angle of inclination is reached.

While doing that, the swing-away lattice could slip off an unsuitable structure, fold down and cause personal injury.

Risk of accidents when RCL is overridden!

Never override the RCL if the crane movements are switched off. In this way you prevent the superstructure from being slewed out of the permissible working range and the truck crane tipping over as a result.

• Enter the correct RCL code for the current rigging mode of the truck crane;

à Tragfähigkeitstabelle.

• Slew the superstructure into an operating position permitted by the lifting capacity table for the RCL rigging code set.

H

The following diagrams each show an example of a crane.

• Extend the main boom as far as is permitted for the RCL rigging code set, or as far as possible given the space available.

• Lower the main boom until the swing-away lattice head touches the ground.

• If the ground cannot be reached, you can

à p. 5 - 74.

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incline the truck crane further;

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Swing-away lattice 4.3 Rigging work

H

In the steps which follow, the swing-away lattice head is pulled or pushed over the ground. Lay boards, for example, under the skids on the head so that it is not pushed into the ground or damaged.

• If necessary, relieve the load on the pin (1) by raising slightly.

• Move the pin (1) into the position for the

à

Setting the angle angle required, e.g. 20°; - with an auxiliary crane, p. 5 - 68.

• Raise the main boom slowly.

When doing so, the head of the swing-away lattice will be pulled across the ground.

• Raise the main boom until the swing-away lattice head is no longer touching the ground.

The swing-away lattice will then be inclined by the angle set, e.g. 20°.

If you inclined the truck crane using the outriggers in order to set the angle, align it to the horizontal again.

• Fully retract the main boom. While doing so, the swing-away lattice must not touch the ground (raise now and then if necessary).

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Swing-away lattice 4.3 Rigging work

• Set the head of the swing-away lattice down on the ground.

• Slowly lower the main boom into a horizontal position.

When doing so, the head of the swing-away lattice will be pushed across the ground.

The swing-away lattice is now in the right position for attaching the hoist rope.

G Setting a 0° angle

Risk of overturning when truck crane is standing at an angle!

After setting the angle, always check whether the truck crane is aligned to the horizontal.

In this way you prevent the actual working range differing from the permitted working range, leading to the truck crane tipping over.

The section assumes that no load has been raised and that the hook block has been unreeved.

• Set the head of the swing-away lattice down on the ground.

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H

In the steps which follow, the swing-away lattice head is pulled or pushed over the ground. Lay boards, for example, under the skids on the head so that it is not pushed into the ground or damaged.

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Swing-away lattice 4.3 Rigging work

• Slowly lower the main boom into a horizontal position.

When doing so, the head of the lattice extension will be pushed across the ground.

• Remove the hoist rope (1) and set it down beside the swing-away lattice.

• Slowly lower the main boom until the swing-away lattice head is no longer touching the ground.

• Extend the main boom as far as is permitted for the RCL rigging code set, or as far as possible given the space available.

• Lower the main boom until the swing-away lattice head touches the ground.

• If the ground cannot be reached, you can incline the truck crane further;

à p. 5 - 74.

• Slowly lower the main boom until the 0° angle is reached.

When doing so, the head of the swing-away lattice will be pushed across the ground.

• Put the pin (1) of the angle piece into the

à

Setting the angle position for a 0° angle; with an auxiliary crane, p. 5 - 68.

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Swing-away lattice 4.3 Rigging work

• Derrick the main boom into the horizontal position and retract it completely.

The swing-away lattice is now in the right position to continue unrigging.

H Inclining the truck crane

If you inclined the truck crane using the outriggers, align it to the horizontal now so that the swing-away lattice sections can be folded more easily.

For inclining, you must set the swing-away lattice down on the ground by extending and lowering the main boom.

Depending on the space available, the condition of the terrain or a limitation on the telescoping due to the current rigging mode, it may be that the swing-away lattice cannot be set down on the ground by telescoping and lowering the main boom.

In this case, you can use the outriggers to incline the truck crane.

G

Risk of accidents if the wheels touch the ground!

Make sure that the wheels do not touch the ground when the truck crane has been inclined. In this way you prevent a reduction in the stability of the truck crane, which could lead to it tipping over when setting the angle.

• Extend the supporting cylinders on the counterweight side.

• Retract the supporting cylinders on the main boom side, if necessary.

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Be sure that the wheels do not touch the ground when doing this.

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Swing-away lattice 4.3 Rigging work

4.3.14

Folding the deflection sheaves out/in

Folding out

G

Risk of crushing!

Always hold the deflection sheave firmly by the handle when removing the pin.

Your fingers can be crushed if you hold a sheave by the side panel.

Rear sheave

• (A) – Hold the deflection sheave (4) by the handle (1) and pull out the pin (2).

• (B) – Fold the deflection sheave (4) upwards until it is aligned with the connecting point (3).

• Insert the pin (2) into the connecting point.

• Secure the pin.

Front sheave

• (A) – Hold the deflection sheave (2) by the handle (1) and pull out the pin (3).

• (B) – Fold the deflection sheave (2) upwards until it is aligned with the connecting point.

• Insert the pin (3) into the connecting point.

• Secure the pin.

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Swing-away lattice 4.3 Rigging work

Folding in

G G

You must fold in the deflection sheaves in order to drive with a folded swing-away lattice.

Risk of accidents by exceeding total permissible height!

Fold in the deflection sheaves when the swing-away lattice is folded on the main boom for driving. When the deflection sheaves are folded out, the overall height specified for on-road driving is exceeded.

Risk of crushing!

Always hold the deflection sheave firmly by the handle when removing the pin.

Your fingers can be crushed if you hold a sheave by the side panel.

Rear sheave

• (A) – Hold the deflection sheave (4) by the handle (1) and pull out the pin (2).

• (B) – Fold the deflection sheave (4) downwards until it is aligned with the connecting point.

• Insert the pin (2) into the connecting point.

• Secure the pin.

Front sheave

• (A) – Hold the deflection sheave (2) by the handle (1) and pull out the pin (3).

• (B) – Fold the deflection sheave (2) downwards until it is aligned with the connecting point.

• Insert the pin (3) into the connecting point.

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• Secure the pin.

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4.3.15

Establishing/disconnecting the electrical connections

Connecting Connecting the electrical connections

• Unwind the cable (3) from the clamp (4).

• Remove the plug (2) from the dummy socket (5) and plug it into the socket (1).

• Lay the cable (3) in such a way that it will not be damaged during crane operation and when swinging the swing-away lattice.

Making the connections for the camera

• Unwind the cable (3) from the clamp (4).

• Insert the plug (2) in the socket (1).

• Lay the cable (3) in such a way that it will not be damaged during crane operation and when swinging the swing-away lattice.

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Swing-away lattice 4.3 Rigging work

Disconnecting Disconnecting – for the electrical system

• Remove the plug (2) from the socket (1) and plug it into the dummy socket (5).

• Wind the cable (3) on to the holder (4).

• Cover the socket (1) with the cap.

Disconnecting – for the camera

• Remove the plug (2) from the socket (1).

• Wind the cable (3) on to the holder (4).

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• Cover the plug and socket with caps.

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4.3.16

Relieving the connecting points

Without hydraulic rigging aid

• Sling section 2 onto an auxiliary crane.

• Carefully raise the swing-away lattice until the connecting points (1) align or until the load has been removed from the pins.

With hydraulic rigging aid The hydraulic cylinder (2) is operated with the hand pump (1) to push the swing-away lattice away from the main boom until the pin (3) can be inserted.

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Swing-away lattice 4.3 Rigging work

When rigging Prerequisites: – The swing-away lattice is swung in front of the main boom.

– The connection (5) is established. The pin is secured.

• Close the valve (2) (turn to the right).

• Move the lever (1) up and down. This extends the hydraulic cylinder (3). Move the hand lever (1) until the bores at the connecting points (4) are aligned.

• Fit the pin on the connecting point (4) and secure it.

• Open the valve (2) (turn to the left).

When unrigging

• First pull the pin out of the connecting point (6).

If the pin cannot be pulled, take the load off the pin.

• Close the valve (2).

• Move the lever (1) up and down. This extends the hydraulic cylinder (3). Move the lever (1) until the pin on the connecting point (6) is relieved.

• Unplug the pin from the connecting point (6), plug it into holder (4) and secure it.

• Slowly open the valve (2).

• Remove the pin from connecting point (5)

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and insert it into holder (4).

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Swing-away lattice 4.3 Rigging work

4.3.17

G S When rigging into the working position

Swinging the swing-away lattice when rigging Risk of accidents due to uncontrolled swinging of the swing-away lattice!

Ensure that no people or objects are in the swinging range and always swing the swing-away lattice with a guide rope from the ground.

Risk of damage to electrical and hydraulic connections!

Ensure that the electrical connection is not trapped/jammed when swinging.

• Check that the following conditions are met:

à p. 5 - 53.

– The rear, centre 2 and front connections are disconnected; à p. 5 - 56, – The swing-away lattice is secured with a guide rope; p. 5 - 58 and p. 5 - 59.

– The slewing connection (1) has been established;

à p. 5 - 67.

• Fold in the fall-back guard (1); à p. 5 - 60.

The fall-back guard (1) may only be folded in immediately before swinging the swing-away lattice. This prevents the swing-away lattice from swinging unexpectedly.

Swinging the swing-away lattice in front of the main boom head

• Swing the swing-away lattice in front of the main boom head using the guide rope so that the connecting points (1) line up.

• An extra person must keep the guide rope tightly tensioned or you must fasten the guide rope so that the swing-away lattice cannot slew back before the connection between the swing-away lattice and the main boom has been established at connecting point (1).

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Swing-away lattice 4.3 Rigging work

When rigging in the transport position

• Check that the following conditions are met: – The swing-away lattice is secured with a guide rope; – The slewing connection (1) has been established;

– The fall-back guard (1) is folded out;

à p. 5 - 53.

à p. 5 - 67.

à p. 5 - 60.

Swinging the swing-away lattice on to the main boom

• Swing the swing-away lattice onto the main boom using the guide rope so that the rear connection (1) engages; connection, p. 5 - 56.

à Establishing/separating the rear

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The swing-away lattice rolls on the support (2) over the folded out fall-back guard (1). The fall-back guard fold out automatically when the swing-away lattice has rolled over it. The fall-back guard prevents the swing-away lattice from swinging unexpectedly.

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Swing-away lattice 4.3 Rigging work

4.3.18

G S

Slewing section 1 Risk of accidents through section1 1 swinging round!

Ensure that no people or objects are in the slewing range of the section and always swing section 1 with a guide rope from the ground.

Risk of damage to the electrical connection!

Ensure that the electrical connection is not trapped/jammed when swinging.

A guide rope must be attached to section 1;

à p. 5 - 53.

Swinging section 1 in front of section 2

• Swing section 1 in front of section 2 using the guide rope so that the connecting points line up.

• An extra person must keep the guide rope tightly tensioned or you must fasten the guide rope so that section 1 cannot swing back before the connection between the sections has been established.

Swinging section 1 onto section 2

• Swing section 1 onto section 2 using the guide rope.

• An extra person must keep the guide rope tightly tensioned or you must

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fasten the guide rope so that section 1 cannot slew back until the Folded connection between the sections has been established.

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Swing-away lattice 4.3 Rigging work

4.3.19

Connections on the left/right of the main boom head

H

G Establishing connections

If the pins cannot be inserted or pulled out, relieve the strain from the connecting points; p. 5 - 79.

à

Risk of accidents due to the swing-away lattice swinging of its own accord!

Always secure the swing-away lattice with a guide rope before disconnecting any connections.

This will prevent the swing-away lattice from swinging around of its own accord and causing injury to you or other persons.

When rigging in the working position or transport position:

• Ensure that the slewing connection is established; à p. 5 - 67.

A guide rope must be attached

à p. 5 - 53.

• Align the connecting points (2).

Right hand connections

• Remove the two pins (1) from of the holder (3).

• Insert the pins (1) in into the connecting points (2).

• Secure the pins.

Left-hand connection

• Remove the two pins (1) from of the holder (3).

• Insert the pins into the connecting points (2).

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• Secure the pins.

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Swing-away lattice 4.3 Rigging work

Separating connections

When rigging in the working position or transport position:

• Ensure that the slewing connection is established; à p. 5 - 67.

A guide rope must be attached;

à p. 5 - 53.

Right-hand connection

• Remove the pins (1) from the connecting points (2).

• Insert the pins (1) into the holder (3).

• Secure the pins.

Left-hand connection

• Remove the pins (1) from the connecting points (2).

• Insert the pins (1) into the holder (3).

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• Secure the pins.

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Swing-away lattice 4.3 Rigging work

4.3.20

G

Attaching/removing the hoist rope Risk of accidents due to falling parts!

To secure the hoist rope, secure the sheaves and rods with retaining pins.

This prevents elements from coming loose or falling and causing injuries.

You can use the rigging hook for this;

à p. 3 - 17.

Attaching

• Remove the sheaves (5) and rods (5).

• Guide the hoist rope via the deflection sheaves (1) and (2) and over the sheave (3) or (4).

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• Install all sheaves (5) and rods (5).

• Secure the rods (5).

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Swing-away lattice 4.3 Rigging work

Removing

• Remove the sheaves (5) and rods (5).

• Remove the hoist rope from the sheave (3) or (4) and the deflection sheaves (1) and (2).

• Lay the hoist rope down on the ground at the left-hand side or roll it onto the drum up to the main boom head/hoist.

• Install all sheaves (5) and rods (5).

• Secure the rods (5).

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Swing-away lattice 4.3 Rigging work

Possible reeving methods

Reeving the hoist rope into the hook block; 1.

à Betriebsanleitung GMK 4100L-

1-sheave hook block Reeving A

2-fall

B

1-fall

Hook tackle Reeving C

1-fall

Only for combination A:

• With a 2-fall reeving, fasten the rope end clamp to the rope attachment

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point (1).

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Swing-away lattice 4.3 Rigging work

4.3.21

Installing/removing the lifting limit switch

Installation

If only a single lifting limit switch is available you must use the lifting limit Betriebsanleitung GMK4100L-1. switch belonging to the main boom;

à

If several lifting limit switches are available, all those lifting limit switches on the main boom from which no lifting limit switch weight is suspended must be overridden; Betriebsanleitung GMK4100L-1.

à

On section 1

• Plug the lifting limit switch (4) into the clamp (3).

• Secure the lifting limit switch.

• Fasten the cable in the clamp (6). Fasten the cable so that it does not sag during crane operation and thus might be damaged.

• Insert the plug (2) in the socket (1).

• Install the lifting limit switch weight (5) and lay it around the hoist rope; Betriebsanleitung GMK 4100L-1.

à

On section 2

• Plug the lifting limit switch (4) into the clamp (3).

• Secure the lifting limit switch.

• Fasten the cable in the clamp (6). Fasten the cable so that it does not sag during crane operation and thus might be damaged.

• Insert the plug (2) in the socket (1).

• Install the lifting limit switch weight (5) and lay it around the hoist rope; Betriebsanleitung GMK 4100L-1.

à

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Swing-away lattice 4.3 Rigging work

Removing From section 1

• Remove the lifting limit switch weight (5);

à Betriebsanleitung GMK4100L-1.

• Remove the plug (2) from the socket (1).

• Cover the socket (1) with the cap.

• Remove the cable from the clamp (6).

• Remove the lifting limit switch (4) from the holder (3).

• Stow the lifting limit switch so that it is safe in traffic, or install it on the main boom; Betriebsanleitung GMK4100L-1.

à

From section 2

• Remove the lifting limit switch weight (5);

à Betriebsanleitung GMK4100L-1.

• Remove the plug (2) from the socket (1).

• Cover the socket (1) with the cap.

• Remove the cable from the clamp (6).

• Remove the lifting limit switch (4) from the holder (3).

• Stow the lifting limit switch so that it is safe in traffic, or install it on the main boom; Betriebsanleitung GMK4100L-1.

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à

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Swing-away lattice 4.3 Rigging work

4.3.22

Installing/removing the anemometer and air traffic control light

Installation

The anemometer and the air traffic control light – if provided – are located on the same rod.

On section 1

• Insert the rod (5) into the clamp (3) and secure it.

• Remove the cables from the holders (4) and connect: – the anemometer to the socket (1), – the air traffic control light to the socket (2).

• Lay the cables in such a way that they will not be damaged during crane operation.

• Check that the anemometer is able to swing so that it hangs vertically even when the main boom is raised.

On section 2

• Insert the rod (5) into the clamp (3) and secure it.

• Remove the cables from the holders (4) and connect: – the anemometer to the socket (2), – the air traffic control light to the socket (1).

• Lay the cables in such a way that they will not be damaged during crane operation.

• Check that the anemometer is able to swing so that it hangs vertically even when the main boom is raised.

Switching the air traffic control light on and off; GMK4100L-1.

à Betriebsanleitung

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Swing-away lattice 4.3 Rigging work

Removing

You must remove the rod with the anemometer/air traffic control light before driving on the road.

• Switch off the air traffic control light.

From section 1

• Remove the plug and close the sockets (1) and (2) with caps.

• Wind the cables on to the clamps (4).

• Remove the rod (5) from the clamp (3).

Stow away the anemometer so that it is safe in Betriebsanleitung GMK4100L-1. traffic;

à

From section 2

• Remove the plug and close the sockets (1) and (2) with caps.

• Wind the cables on to the clamps (4).

• Remove the rod (5) from the clamp (3).

• Stow away the anemometer so that it is safe in

à Betriebsanleitung GMK4100L-1.

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Swing-away lattice 4.3 Rigging work

4.3.23

Installing/removing the camera Operating the camera;

à Betriebsanleitung GMK4100L-1.

Installation On section 1

• Insert the camera (2) into the clamp (1) and secure it.

• Insert the plug (4) in the socket (3).

• Lay the cable (5) so that it will not be damaged during crane operation.

On section 2

• Insert the camera (2) into the clamp (1) and secure it.

• Insert the plug (4) in the socket (3).

• Lay the cable (5) so that it will not be damaged during crane operation.

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Swing-away lattice 4.3 Rigging work

Removing From section 1

• Take the plug (3) out of the socket (4) and close the socket with the cap.

• Remove the camera (2) from the clamp (1) and fasten the retaining pin in the clamp.

• Stow away the camera so that it will not be damaged during crane operation.

From section 2

• Take the plug (3) out of the socket (4) and close the socket with the cap.

• Remove the camera (2) from the clamp (1) and insert the retaining pin in the clamp.

• Stow away the camera so that it will not be

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Swing-away lattice 4.3 Rigging work

4.3.24

Main boom operation with a folded swing-away lattice – rigging mode The swing-away lattice must be manually swung outwards via a guide rope and fastened before telescoping.

The telescopic sections cannot move past the swing-away lattice when the swing-away lattice is fully folded. Telescoping of the main boom is then blocked.

To prevent damage to the swing-away lattice, you must establish the rigging mode specified below before the main boom is telescoped.

S

Risk of damage during telescoping!

Ensure that the rigging mode specified here is established before the main boom is telescoped.

This prevents the connecting points from being damaged or torn off.

Ensure that: – The slewing connection is separated;

à p. 5 - 67.

– The Front connection has been established;

à p. 5 - 59.

– The connection between section 1 - section 2 at the right has been p. 5 - 61. established;

à

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Swing-away lattice 4.3 Rigging work

– The Rear connection has been established;

à p. 5 - 56.

– The Folded connection has been established;

à p. 5 - 64.

à p. 5 - 58.

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– The Centre 2 connection has been established;

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Swing-away lattice 4.4 Operation with a swing-away lattice

4.4

Operation with a swing-away lattice The raising, lowering, slewing, derricking and telescoping movements of the main boom are carried out in the same way as when operating with the main boom. This section only contains information that you will additionally need for a rigged or installed swing-away lattice.

4.4.1

Setting the RCL

Input

• Enter the current rigging mode for operation with a rigged swing-away lattice into the RCL. Use either the corresponding RCL code in accordance with the Lifting capacity table (1) or via individual components (2).

When you input the current rigging mode for the individual components you must also input – Enter the length before the angle (1), – length after the angle (2).

– Enter the configured lattice extension angle (3).

• Enter the current reeving on the swing-away lattice for the hoisting gear whose hoist rope is reeved on the swing-away lattice into the RCL.

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• Confirm the entry.

H

The lifting capacity for the RCL code is enabled once the telescopic sections are locked.

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Swing-away lattice 4.4 Operation with a swing-away lattice

Shutdown

Operation with the swing-away lattice is monitored by the RCL. When operating with the swing-away lattice, RCL shutdowns may occur for the same reasons as when operating with the main boom; Betriebsanleitung GMK4100L-1.

à

In certain rigging modes, the RCL shuts down when lifting loads that are lighter than the maximum load bearing capacity specified in the lifting capacity table.

– During operation with the swing-away lattice If a hook block (3) is reeved at the main boom, then the displayed current load (1) is influenced by – the weight of the lifted load (2) and – the weight of the hook block (3).

– During main boom operation If a hook block (3) is reeved at the swing-away lattice, then the displayed current load (1) is influenced by – the weight of the lifted load (2), – the weight of the swing-away lattice (4) and – the weight of the hook block (3).

4.4.2

Derricking the main boom

Slewing range of 360°

G

Risk of accidents if the RCL is overridden!

Do not override the RCL when lowering the boom into horizontal position.

If the RCL is overridden, the crane operation will not be monitored and the truck crane will overturn if it moves outside of the permissible working range.

The prerequisites for permitting raising and lowering of the main boom with a rigged swing-away lattice over a slewing range of 360° are monitored by the RCL. Further information on the permissible angle ranges and lifting capacities is provided in the Lifting capacity table; Rigging tables – lattice extension.

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à

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Swing-away lattice 4.4 Operation with a swing-away lattice

4.4.3

Telescoping with a rigged swing-away lattice

Slewing range of 360°

S

Risk of overloading the main boom!

If you are telescoping the main boom with the rigged swing-away lattice, you may not simultaneously slew the superstructure.

This prevents the main boom from being overloaded by additional lateral forces and increased vibration.

The telescoping of the main boom with a rigged swing-away lattice (in the operating position) is monitored by the RCL. Telescoping is only released at specific main boom and lattice extension angles when a maximum permissible load is not exceeded. Further information on the permissible angles and the maximum permissible load is provided in the lifting capacity tables. This also provides information on the telescoping paths for rigging the swing-away lattice; à Rigging tables – lattice extension.

Telescoping with a folded swingaway lattice Telescoping of the main boom is disabled when the swing-away lattice is not attached to the Front connection (1); Troubleshooting table, p. 5 - 113.

An error message is displayed.

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à

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Swing-away lattice 4.4 Operation with a swing-away lattice

4.4.4

G

Procedure if the permissible wind speed is exceeded Risk of accidents at excessively high wind speeds!

If the current wind speed is higher than the maximum permissible wind speed, cease crane operation immediately and set up the corresponding rigging mode.

This will prevent the truck crane overturning due to overload.

• Prior to and during crane operation, check whether the current wind speed is lower than the maximum permissible wind speed.

• Make sure that you follow the instructions for checking the wind speed;

à Tragfähigkeitstabelle and Betriebsanleitung GMK 4100L-1.

If the maximum permissible wind speed is exceeded An automatic shutdown does not occur if the maximum permissible wind speed is exceeded.

• Immediately cease crane operation.

• Put the truck crane into the rigging mode specified for the current wind

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speed in the lifting capacity table.

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Swing-away lattice 4.4 Operation with a swing-away lattice

4.4.5

Information on the main boom operation when the swing-away lattice is folded/rigged

Folded

Establish the rigging state specified in section Main boom operation with a folded swing-away lattice – rigging mode before telescoping with a folded p. 5 - 95. swing-away lattice;

à

S

Risk of damage during telescoping!

Ensure that the rigging state necessary for telescoping has been established before starting the telescoping process.

This prevents the connecting points at the swing-away lattice from being damaged or torn off.

During main boom operation with a folded swing-away lattice, the loads specified in the lifting capacity table are reduced and displayed on the maximum load RCL display.

H In working position

The Lifting capacity tables contain operational planning information specifying the values that must be subtracted from the specified maximum load bearing capacities for certain rigging modes; Remarks about working with the swing-away lattice.

à

Main boom operation with rigged swing-away lattice combinations A and B (in the operating position) is permitted.

You must enter an RCL code for the main boom without a swing-away lattice in order to operate in this mode. This operating mode is only permissible under certain specific rigging modes.

More information on the permissible rigging modes and the swing-away lattice lengths is provided in the lifting capacity tables; Remarks on working with the swing-away lattice.

à

The lifting capacities specified in the lifting capacity table are reduced for main boom operation with rigged swing-away lattice. The Lifting capacity tables contain operational planning information specifying the values that must be subtracted from the specified maximum load bearing capacities for certain rigging modes; Remarks about working with the swing-away lattice.

à

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Swing-away lattice 4.4 Operation with a swing-away lattice

The RCL display (1) does not display the reduced values correctly.

This means that the displayed value can deviate from the value that was previously calculated during the operations planning.

If this is the case, the RCL is not faulty. Do not override the RCL. Even if the displayed value is higher than the calculated value.

G 4.4.6

Risk of accidents if the RCL is overridden!

Do not under any circumstances override the RCL. If the RCL is overridden, the crane operation will not be monitored and the truck crane will overturn if it moves outside of the permissible working range.

Instructions for turning loads over

à Turning loads over, p. 10 - 1.

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Notes on two-hook operation;

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Swing-away lattice 4.5 Maintenance

4.5

Maintenance

H 4.5.1

If the lattice extension has been in storage for an extended period of time, perform maintenance on it, at the very latest when it is next used.

Maintenance plan M 1

M1

Maintenance work on the LATTICE EXTENSION: monthly/after 100 oper. hrs.

Swing-away lattice – Lubricate the pins – Grease the moving parts at the connections – Check that the fall-back guard moves freely

4.5.2

Maintenance plan M 3

à p. 5 - 105 à p. 5 - 106 à p. 5 - 107

M3

Maintenance work on the LATTICE EXTENSION: Every three months/after 250 oper. hrs.

Swing-away lattice

à p. 5 - 110

– Check the sheaves

4.5.3

Maintenance plan M 12

M 12

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Maintenance work on the LATTICE EXTENSION: Every 12 months/after 1,000 operating hours Swing-away lattice

à p. 5 - 111

– Lubricate joints

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Swing-away lattice 4.5 Maintenance

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Swing-away lattice 4.5 Maintenance

4.5.4

Description of maintenance work

Pins Grease 1) Grease 1)

Designation to DIN 51502

Specifications Classification

GROVE Section no.1)

KP - 1K - 50

DIN 51825

03233369

à Wartungsanleitung

Prerequisite – The truck crane is secured against unauthorised use; Wartungsanleitung.

à

or – The swing-away lattice is removed;

à p. 5 - 24.

Lubricating the pins

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• Lubricate the locking pins specified here.

– the pins (2) and (3) at the deflection sheaves, – the pins (2) at the head sheave of section 1, – the pins (2) at the head sheave of section 2, – the pins (1) at the connection section 1 – section 2, – the pins (4) for the connections between the swing-away lattice and main boom, – the swivel pins (5).

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Swing-away lattice 4.5 Maintenance

Connections

Grease the moving parts

Grease 1) Grease 1)

Designation to DIN 51502

Specifications Classification

GROVE Section no.1)

KP - 1K - 50

DIN 51825

03233369

à Wartungsanleitung

Prerequisite – The truck crane is secured against unauthorised use; Wartungsanleitung.

à

or – The swing-away lattice is removed;

à p. 5 - 24.

At the rear connection:

• Check that the parts are complete and undamaged.

• Have missing, damaged or worn parts replaced by Manitowoc Crane Care or an authorised GROVE dealer or your repair crew.

• Remove old grease from the pin (1) and the pin (2).

• Lightly grease the pin (1) and the pin (2).

• Move the pins back and forth to distribute

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the grease.

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Swing-away lattice 4.5 Maintenance

Fall-back guard

Check for freedom of movement Grease 1) Grease 1)

Designation to DIN 51502

Specifications Classification

GROVE Section no.1)

KP - 1K - 50

DIN 51825

03233369

à Wartungsanleitung

Prerequisite – The truck crane is secured against unauthorised use; Wartungsanleitung.

à

– The swing-away lattice is swung to the side of the main boom. or – The swing-away lattice is removed;

à p. 5 - 24.

Swinging the swing-away lattice on to the main boom 1. Attach the guide rope to the rear of section 2;

2. Separate the Front connection; lattice with the guide rope.

à p. 5 - 53.

à p. 5 - 59. Hold the swing-away

3. Pull the swing-away lattice onto the main boom using the guide rope until the slewing connections are aligned.

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Swing-away lattice 4.5 Maintenance

4. Establish the lower slewing connection

à p. 5 - 67.

Check

• Check that the fall-back guard (1) is complete.

Check that the parts are complete, undamaged and are not worn out.

• Have missing, damaged or worn parts replaced by Manitowoc Crane Care or an authorised GROVE dealer or your repair crew.

Check that the fall-back guard moves freely.

The fall-back guard must fall back into the vertical position under its own weight.

• Manually screw the fall-back guard (1) in.

• Let go of the fall-back guard.

• Move the fall-back guard back and forth.

If the fall-back guard does not move freely:

• Grease it and check that it moves freely.

• Check that the fall-back guard folds out automatically when the locking bar (2) is released.; p. 5 - 60.

à

If the fall-back guard does not fold out automatically:

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• Grease it and check that it moves freely.

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Swing-away lattice 4.5 Maintenance

Lubricating the fall-back guard

• Remove any old grease from the fall-back guard (1) from above and below.

• Lightly grease the fall-back guard (1) from above.

• Lightly grease the locking bar (2) from below.

• Move the locking bar (2) back and forth to distribute the grease.

Bringing the swing-away lattice into the transport position 1. Check that the fall-back guard (1) is folded out. Fold out if necessary; p. 5 - 60.

à

2. Disconnect the lower slewing connection

à p. 5 - 67.

3. Pull the swing-away lattice outwards using the guide rope until it rests on the fall-back guard.

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Swing-away lattice 4.5 Maintenance

4. Establish the front connection;

à p. 5 - 59.

5. Remove the guide rope.

Rollers Grease 1) Grease 1)

Designation to DIN 51502

Specifications Classification

GROVE Section no.1)

KP - 1K - 50

DIN 51825

03233369

à Wartungsanleitung

Check the sheaves Check all sheaves specified here for damage, wear, mobility and heavy soiling.

• Check the deflection sheaves (1) and (2).

• Check the head sheave (3) and (4).

• Have damaged, worn, stiff or extremely soiled sheaves replaced by 07.11.2018

Manitowoc Crane Careor an authorised GROVE dealer or your repair crew.

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Swing-away lattice 4.5 Maintenance

Joints Grease 1) Grease 1)

Designation to DIN 51502

Specifications Classification

GROVE Section no.1)

KP - 1K - 50

DIN 51825

03233369

à Wartungsanleitung

– Grease gun Prerequisite – The truck crane is secured against unauthorised use; Wartungsanleitung.

à

or – The swing-away lattice is removed;

à p. 5 - 24.

Lubricate joints Section 2 is fitted with two grease nipples (1).

• Clean the grease nipples (1).

• Press grease into the grease nipples (1) until new grease comes out at the lubricating point.

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• Remove any grease that has escaped.

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Swing-away lattice 4.5 Maintenance

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Swing-away lattice 4.6 Finding and eliminating malfunctions

4.6

Finding and eliminating malfunctions

4.6.1

Troubleshooting table

Malfunction

Cause

Solution

Lifting limit switch switches off (lamp (1) lights up)

Lifting limit switch not connected.

Connect the lifting limit switch; p. 5 - 89.

There is a second lifting limit switch connected to the main boom and it is not locked.

à Betriebsanleitung GMK

à

Block the lifting limit switch;

4100L-1.

Electrical connections are not connected during extending and retracting.

Establishing the electrical connection; p. 5 - 77.

The main boom cannot be telescoped when the swingaway lattice is rigged

The main boom is at an impermissible angle.

Derrick the main boom to the required angle; p. 5 - 98.

The main boom cannot be telescoped when the swingaway lattice is folded

The slewing connection is not disconnected.

Disconnect the slewing p. 5 - 67. connection; Establish the front connection; p. 5 - 59.

à

à

à

à

Establish the front connection; p. 5 - 59.

à

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The swing-away lattice is swung to the side of the main boom. The slewing connection is separated.

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Swing-away lattice 4.6 Finding and eliminating malfunctions

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Boom extension 5.1 Operations planning

5

Boom extension

5.1

Operations planning

5.1.1

Assembly

S

Risk of overturning in other combinations!

Assemble the boom extension only in the permissible combinations as specified in the lifting capacity table. Other combinations are not monitored by the RCL.

Permissible combinations

Combination

Designation

Z + Y 1)

Sections used

A

Boom extension A 17.4 m

9.7 + 7.7 m

3+2

B

Boom extension B 24.0 m

9.7 + 14.3 m

3+2+1

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1)

Designation in the lifting capacity table: Z = length before setting the angle Y = length after setting the angle

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5-1

Boom extension 5.1 Operations planning

5.1.2

Identification

Section 3

G

Risk of accidents when using an incorrect boom extension!

Install only the section 3 that belongs to the specific truck crane. Other boom extensions must not be installed.

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The truck crane and the corresponding section 3 must be labelled with the same serial number (1).

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Boom extension 5.1 Operations planning

5.1.3

Slinging points

Section 3

G

Risk of accidents if used improperly!

Sling section 3 only at the slinging points provided. Use only lifting gear and joining elements of sufficient load bearing capacity.

The slinging points (1) are marked with stickers (2).

The sticker (3) gives data on the weight and the necessary lifting gear.

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The grille (4) serves as the slinging point for the guide rope.

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5-3

Boom extension 5.1 Operations planning

5.1.4

5.1.5

Transport dimensions and weights

Section

Length x width x height in m

Weight in kg

3

8.15 x 0.70 x 1.15

600

Transport condition

Section 3

• Check the transport condition and establish this now, if necessary.

– All electrical cables (1) are closed with caps.

– The plug (2) has been inserted in the dummy socket.

– The deflection sheave (3) is folded in and secured.

– Section 3 is set down on a suitable base and (4) secured.

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– All pins (5) must be secured in the clamps.

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Boom extension 5.2 Checklists for rigging work

5.2

Checklists for rigging work

5.2.1

Overview The following table shows which checklist is applicable for any required rigging work.

Required rigging work

checklist

– installing the boom extension

CHECKLIST: installing the boom extension, p. 5 - 6

– removing the boom extension

CHECKLIST: removing the boom extension, p. 5 - 9

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Boom extension

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Boom extension 5.2 Checklists for rigging work

5.2.2

CHECKLIST: installing the boom extension

H

This checklist is not equivalent to the complete operating instructions.

There are accompanying operating instructions which are indicated by cross-references.

Observe the warnings and safety instructions there!

1. Prerequisite

à

– The truck crane is supported on outriggers; Betriebsanleitung GMK4100L-1.

– The appropriate counterweight for the crane operation must be rigged; Betriebsanleitung GMK4100L-1.

– The main boom must be completely retracted and lowered into horizontal position; Betriebsanleitung GMK4100L-1.

– The swing-away lattice is removed.

– An auxiliary crane must be available.

à

à

2. Check the transport condition of section 3;

à p. 5 - 4.

3. Fold out the deflection sheave on section 3 and secure it;

à p. 5 - 13.

4. – Fasten slings to section 3 and attach a guide rope.

à Identification, p. 5 - 2, à Slinging points, p. 5 - 3. à Transport dimensions and weights, p. 5 - 4, 5-6

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– Lift section 3 into position in front of the main boom.

Boom extension 5.2 Checklists for rigging work

5. – Establish a mechanical connection between section 3 and the main boom; p. 5 - 14.

à

– Remove the lifting gear and the guide rope.

6. Establish the electrical connection between section 3 and the main boom; p. 5 - 15.

à

7. Check the transport condition of the swing-away lattice; condition – removed, p. 4 - 7.

à Transport

8. Fold out the deflection sheave on section 2 and secure it;

à p. 4 - 75.

9. Sling lifting gear to the required swing-away lattice sections, depending on the boom extension A or B, and attach a guide rope.

à Assembly, p. 5 - 1. à Slinging points, p. 4 - 4.

10. – Lift the swing-away lattice in front of section 3.

– Establish the connection between section 3 and the swing-away lattice; p. 5 - 14.

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à

– Remove the lifting gear and the guide rope.

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5-7

Boom extension 5.2 Checklists for rigging work

11. Establish the electrical connection between section 3 and the swingaway lattice; p. 5 - 17.

à

12. Position the hoist rope on section 3;

s

H

à p. 5 - 20.

Further installation is performed in the same manner as installation of the swing-away lattice. This is described in the checklist CHECKLIST: Installing the swing-away lattice – into the working position.

13. Perform the required steps.

– For boom extension A Perform all steps for installing the swing-away lattice 1.7 + 7.7 m starting from point 8.; p. 4 - 18.

à

– For boom extension B Perform all steps for installing the swing-away lattice 1.7 + 14.3 m starting from point 9.; p. 4 - 19.

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à

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Boom extension 5.2 Checklists for rigging work

5.2.3

CHECKLIST: removing the boom extension

H

This checklist is not equivalent to the complete operating instructions.

There are accompanying operating instructions which are indicated by cross-references.

Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is supported on outriggers; GMK4100L-1.

à Betriebsanleitung

– The appropriate counterweight for the crane operation must be Betriebsanleitung GMK4100L-1. rigged;

à

– The main boom must be completely retracted and lowered into Betriebsanleitung GMK4100L-1. horizontal position;

à

– An auxiliary crane must be available.

H

Removal is started in the same manner as removal of the swing-away lattice. This is described in the checklist CHECKLIST: Removing the swingaway lattice – from the working position.

2. Perform the required steps.

– For boom extension A Perform all steps for removing the swing-away lattice 1.7 + 7.7 m up to and including point 5. ; p. 4 - 24.

à

– For boom extension B Perform all steps for removing the swing-away lattice 1.7 + 14.3 m p. 4 - 24. up to and including point 6.;

à

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5-9

Boom extension 5.2 Checklists for rigging work

3. Unreeve the hoist rope and remove it from section 3;

à p. 5 - 20.

If necessary, roll the hoist rope onto drum up to the main boom head.

4. Sling lifting gear to the required swing-away lattice sections, depending on the boom extension A or B, and attach a guide rope.

à à

– Sections required; p. 4 - 1. p. 4 - 4.

– Slinging points;

5. Disconnect the electrical connection between section 3 and the swingp. 5 - 18. away lattice;

à

6. Disconnect the connection between section 3 and the main boom; p. 5 - 19.

à

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7. Lift the swing-away lattice off section 3 and set it down.

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Boom extension 5.2 Checklists for rigging work

8. Fold in the deflection sheave on section 2 and secure it;

à p. 4 - 75.

9. Secure the swing-away lattice in the transport condition; condition – removed, p. 4 - 7.

à Transport

10. Disconnect the electrical connection between section 3 and the main boom; p. 5 - 16.

à

11. Fasten slings to section 3 and attach a guide rope: Identification, p. 5 - 2, Transport dimensions and weights, p. 5 - 4, Slinging points, p. 5 - 3.

à à à

12. Disconnect the connection between section 3 and the main boom; p. 5 - 14.

à

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5 - 11

Boom extension 5.2 Checklists for rigging work

13. Lift section 3 off the main boom and put it aside.

14. Fold in and secure the deflection sheave at section 3;

15. Secure section 3 in the transport condition;

à p. 5 - 13.

à p. 5 - 4.

16. Reeve the hoist rope onto the main boom head, or roll it on to the drum; Betriebsanleitung GMK4100L-1.

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à

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Boom extension 5.3 Description of the rigging work

5.3

Description of the rigging work

5.3.1

Folding the deflection sheave out/in – section 3

G

Risk of crushing!

Always hold the deflection sheave firmly by the handle when removing the pins.

Your fingers may be crushed if you hold the sheave by the side panel.

Folding out

• (A) – Hold the deflection sheave (2) firmly by the handle (1) and pull out the pin (3).

• (B)– Fold the deflection sheave (2) upwards until the connecting points align.

• Insert the pins (3) into the connecting points.

• Secure the pins.

Folding in

• (A) – Hold the deflection sheave (2) firmly by the handle (1) and pull out the pin (3).

• Fold the deflection sheave (2) downwards until the connecting points align.

• Insert the pins (3) into the connecting points.

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• Secure the pins.

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5 - 13

Boom extension 5.3 Description of the rigging work

5.3.2

G

Installing/removing section 3 on/from the main boom Risk of accident if used improperly!

Sling section 3 only at the slinging points provided. Use only lifting gear and joining elements of sufficient load bearing capacity.

– Section 3 must be attached to an auxiliary crane.

– A guide rope must be attached p. 5 - 3.

à

Installing

• Align the connecting points (1).

• Remove the pins (3) from the clamps (2) and insert them into the connecting points (1).

• Secure the pins.

• Disconnect the guide rope and the lifting gear.

Removing

• Remove the pins (3) from the connecting points (1) and insert them into the clamps (2).

• Secure the pins.

• Disconnect the guide rope and the lifting

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gear.

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Boom extension 5.3 Description of the rigging work

5.3.3

Connecting/disconnecting the electrical connections – section 3/main boom Making the electrical connections

• Unwind the cable (3) from the clamp (4).

• Remove the plug (2) from the dummy socket (5) and plug it into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Making the connections for the camera

• Unwind the cable (3) from the clamp (4).

• Insert the plug (2) in the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

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5 - 15

Boom extension 5.3 Description of the rigging work

Disconnecting – for electrical system

• Remove the plug (2) from the socket (1) and plug it into the dummy socket (5).

• Wind the cable (3) on to the holder (4).

• Cover the socket (1) with the cap.

Disconnecting – for the camera

• Remove the plug (2) from the socket (1).

• Wind the cable (3) on to the holder (4).

• Close the plug (2) and the socket (1) with the caps.

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•

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Boom extension 5.3 Description of the rigging work

5.3.4

G

Connecting/disconnecting the electrical connections – section 3/swing-away lattice

Risk of hands and arms being crushed!

The unlocked swing-away lattice can swing. Therefore, do not reach between section 3 and the swing-away lattice. This will prevent your arms or hands from being crushed.

Lay the cable so that it will not be damaged during crane operation.

Making the electrical connections

• Unwind the cable (3) from the clamp (4).

• Remove the plug (2) from the dummy socket (5) and plug it into the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

Making the connections for the camera

• Unwind the cable (3) from the clamp (4).

• Insert the plug (2) in the socket (1).

• Lay the cable (3) so that it will not be damaged during crane operation.

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5 - 17

Boom extension 5.3 Description of the rigging work

Disconnecting – for electrical system

• Remove the plug (2) from the socket (1) and plug it into the dummy socket (5).

• Wind the cable (3) on to the holder (4).

• Cover the socket (1) with the cap.

Disconnecting – for the camera

• Remove the plug (2) from the socket (1).

• Wind the cable (3) on to the holder (4).

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• Cover the plug and socket (1) with caps.

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Boom extension 5.3 Description of the rigging work

5.3.5

Installing/removing the swing-away lattice on/from section 3 – The swing-away lattice must be attached to an auxiliary crane.

– A guide rope must be attached.

Installing

• Align the connecting points (2).

• Remove the pins (1) from the clamps (3) and insert them into the connecting points (1).

• Secure the pins.

• Disconnect the guide rope and the lifting gear.

Removing

• Remove the pins (2) from the connecting points (1) and insert them into the clamps (3).

• Secure the pins.

• Disconnect the guide rope and the lifting

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5 - 19

Boom extension 5.3 Description of the rigging work

5.3.6

G

Attaching/removing the hoist rope

Risk of accidents due to falling parts!

To secure the hoist rope, secure the sheaves and rods with retaining pins.

This prevents elements from coming loose or falling and causing injuries.

You can use the rigging hook for this;

à p. 3 - 9.

Attaching

• Remove the sheaves (6) and rods (6).

• Guide the hoist rope via the deflection sheaves (1), (2) and (3) and over the head sheave (4) or (5).

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• Install all sheaves (6) and rods (6).

• Secure all sheaves (6) and all rods (6).

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Boom extension 5.3 Description of the rigging work

Removing

• Remove the sheaves (6) and rods (6).

• Remove the hoist rope from the deflection sheaves (1), (2) and (3) and from the head sheaves (4) or (5).

• Lay the hoist rope down on the ground at the left-hand side or roll it onto the drum up to the main boom head/hoist.

• Install all sheaves (6) and rods (6).

• Secure all sheaves (6) and all rods (6).

Possible reeving methods;

à p. 4 - 88.

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Possible reeving methods

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5 - 21

Boom extension 5.3 Description of the rigging work

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Boom extension 5.4 Operation with boom extension

5.4

Operation with boom extension

G

Risk of accidents due to overloading!

Crane operation with the main boom is prohibited when a boom extension is rigged.

Lifting a load with two hooks is prohibited when a boom extension is rigged.

The raising, lowering, slewing, derricking and telescoping movements of the main boom are carried out in the same way as when operating with the main boom. This section only contains information that you will need additionally for a rigged boom extension.

5.4.1

Setting the RCL

Input

• Enter the current rigging mode for operation with a rigged boom extension into the RCL. Use either the corresponding RCL code in accordance with the Lifting capacity table (1) or via individual components (2).

When you input the current rigging mode for the individual components you must also input – Enter the length before the angle (1), – Enter the length after the angle (2), – Enter the configured lattice extension angle (3).

• Enter the current reeving on the boom extension for the hoist whose hoist rope is reeved on the boom extension into the RCL.

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5 - 23

Boom extension 5.4 Operation with boom extension

• Confirm the entry.

H Shutdown

The lifting capacity for the RCL code is enabled once the telescopic sections are locked.

Operation with the boom extension is monitored by the RCL. When operating with the boom extension, RCL shutdowns may occur for the same reasons as when operating with the main boom; Betriebsanleitung GMK4100L-1.

à

In certain rigging modes, the RCL shuts down when lifting loads that are lighter than the maximum load bearing capacity specified in the lifting capacity table.

– During operation with the boom extension If a hook block (3) is reeved at the main boom, then the displayed current load (1) is influenced by – the weight of the lifted load (2) and

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– the weight of the hook block (3).

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Boom extension 5.4 Operation with boom extension

5.4.2

Derricking, telescoping the main boom

Slewing range of 360°

G

Risk of accidents if the RCL is overridden!

Do not override the RCL when lowering the boom into horizontal position.

If the RCL is overridden, the crane operation will not be monitored and the truck crane will overturn if it moves outside of the permissible working range.

The requirements that must be satisfied before raising, lowering and telescoping of the main boom with rigged boom extension are permitted, for a slewing range of 360° are monitored by the RCL. Further information on the permissible angle ranges and lifting capacities is provided in the Lifting capacity table; Rigging tables – lattice extension.

à

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The hook block can hit the main boom if the main boom is set to a steep angle and the boom extension is set to 0°.

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5 - 25

Boom extension 5.4 Operation with boom extension

5.4.3

G

Procedure if the permissible wind speed is exceeded Risk of accidents at excessively high wind speeds!

If the current wind speed is higher than the maximum permissible wind speed, cease crane operation immediately and set up the corresponding rigging mode.

This will prevent the truck crane overturning due to overload.

• Prior to and during crane operation, check whether the current wind speed is lower than the maximum permissible wind speed.

• Be sure to follow the instructions for checking the wind speed;

à Betriebsanleitung GMK4100L-1.

If the maximum permissible wind speed is exceeded An automatic shutdown does not occur if the maximum permissible wind speed is exceeded.

• Immediately cease crane operation.

• Put the truck crane into the rigging mode specified for the current wind speed in the lifting capacity table.

5.4.4

Instructions for turning loads over

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Turning loads over with a rigged boom extension is prohibited.

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Boom extension 5.5 Maintenance

5.5

Maintenance

H 5.5.1

If the lattice extension has been in storage for an extended period of time, perform maintenance on it, at the very latest when it is next used.

Maintenance plan M 1

M1

Maintenance work on the LATTICE EXTENSION: Monthly/after about 100 oper. hrs.

Boom extension

à p. 5 - 28

– Lubricating the pins

5.5.2

Maintenance plan M 3

M3

Maintenance work on the LATTICE EXTENSION: Every three months/after 250 oper. hrs.

Boom extension

à p. 5 - 28

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– Check the sheaves

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5 - 27

Boom extension 5.5 Maintenance

5.5.3

Description of maintenance work Grease 1) Grease 1)

Designation to DIN 51502

Specifications Classification

GROVE Section no.1)

KP - 1K - 50

DIN 51825

03233369

à Wartungsanleitung Lubricating the pins

• Lubricate the pins (1).

Check the sheaves

• Check the deflection sheave (2) for damage, wear, mobility and heavy soiling.

• Have damaged, worn, stiff or extremely soiled

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sheaves replaced by Manitowoc Crane Care or an authorised GROVE dealer or your repair crew.

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Heavy load lattice extension (SLS) 2.0 m 6.1 Operations planning

6

Heavy load lattice extension (SLS) 2.0 m

6.1

Operations planning

6.1.1

Assembly

S

Risk of overturning in other combinations!

Assemble the heavy load lattice extension only in the combinations listed as permissible in the lifting capacity table. Other combinations are not monitored by the RCL. permissible combinations

Sections used

Heavy load lattice extension 2.0 m

6

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Description

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6-1

Heavy load lattice extension (SLS) 2.0 m 6.1 Operations planning

6.1.2

G

Identification Risk of accidents if heavy load lattice extensions are interchanged!

Install only the heavy load lattice extension that belongs to the crane.

No other heavy load lattice extensions may be installed.

Section 6

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The crane and the corresponding section 6 must be labelled with the same serial number (1).

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Heavy load lattice extension (SLS) 2.0 m 6.1 Operations planning

6.1.3

G

Slinging points Risk of accidents if used improperly!

Sling the heavy load lattice extension only at the slinging points provided.

Use only lifting gear and joining elements of sufficient load bearing capacity.

Section 6 The fixed slinging point (1) is marked with a sticker (2).

• Attach the heavy load lattice extension at a 0° angle to the slinging point. Now the heavy load lattice extension hangs in a horizontal position on the auxiliary crane.

The sticker (3) gives data on the weight and the necessary lifting gear.

Dimensions and weights; à Transport dimensions and weights, p. 6 - 4.

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The rope attachment point (4) serves as the slinging point for the guide rope.

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6-3

Heavy load lattice extension (SLS) 2.0 m 6.1 Operations planning

6.1.4

Transport dimensions and weights

Section

Length x width x height in m

Weight in kg

6

2.23 x 0.80 x 1.42

400

6.1.5

Transport condition

Section 6

On the transport vehicle

• Check that the heavy lattice load extension is in the transport condition or establish this now, if necessary: – The angle position (2) must be set to 0° and the pins must be inserted and secured.

– All pins (5) and (6) must be secured in the clamps.

– The chain hoist (4) must be mounted and sufficiently tensioned so that it cannot come loose during transport.

– Section 6 must be secured to a suitable support.

– The lifting limit switch weight must be plugged into the holder (1) and secured.

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– The connecting cable must be wound on to the clamp (3) and the plug and socket closed with a cap.

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Heavy load lattice extension (SLS) 2.0 m 6.1 Operations planning

On the truck crane

• Check that the heavy lattice load extension is in the transport condition or establish this now, if necessary: – The angle position (1) must be set to 0° and the pins must be inserted and secured.

– The lifting limit switch weight must be plugged into the holder (2) and secured.

– The chain hoist must be removed from the slinging points (3) and (4) and stowed safely for road transport.

– The pin (5) must be secured in the clamp.

– The connecting cable must be wound on to the clamp (6) and the plug and socket closed with a cap.

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– The pins (7) and (8) must be secured in the connecting points.

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Heavy load lattice extension (SLS) 2.0 m 6.1 Operations planning

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Heavy load lattice extension (SLS) 2.0 m 6.2 Checklists for rigging work

6.2

Checklists for rigging work

6.2.1

Overview The distinction is made between various different procedures.

– Installation and removal These procedures have to be performed when the lattice extension is being transported separately. The installation and removal of the lattice extension is described.

– Rigging These procedures must be performed when the lattice extension is being transported on the crane. The changeover between the transport position and the operating position is described.

The table shows which checklist is applicable to any required rigging work.

Required rigging work

– Installing the SLS

– Removing the SLS

– In working position

CHECKLIST: SLS 2.0 m installation into the working position, p. 6 - 8

– In transport position

CHECKLIST: SLS 2.0 m installation into the transport position, p. 6 - 11

– From operating position

CHECKLIST: SLS 2.0 m removal from the working position, p. 6 - 12

– From transport position

CHECKLIST: Removing the SLS 2.0 m – from the transport position, p. 6 - 15

– In working position

CHECKLIST: SLS 2.0 m rigging into the working position, p. 6 - 17

– In transport position

CHECKLIST: SLS 2.0 m rigging into the transport position, p. 6 - 21

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– SLS Rigging

Checklist

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Heavy load lattice extension (SLS) 2.0 m 6.2 Checklists for rigging work

6.2.2

CHECKLIST: SLS 2.0 m installation into the working position

H

This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references.

Observe the warnings and safety instructions there.

1. Prerequisite – The truck crane is supported on outriggers; GMK4100L-1.

à Betriebsanleitung

– The appropriate counterweight for the crane operation must be Betriebsanleitung GMK4100L-1. rigged;

à

– The main boom must be completely retracted and lowered into horizontal position; Betriebsanleitung GMK4100L-1.

à

– An auxiliary crane must be available.

2. Check that section 6 is secured in the transport condition;

à p. 6 - 4.

3. Fasten slings to section 6 and attach a guide rope: Identification, p. 6 - 2

à à Transport dimensions and weights, p. 6 - 4 à Slinging points, p. 6 - 3.

4. Lift section 6 into position in front of the main boom and insert the pins; p. 6 - 23.

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à

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Heavy load lattice extension (SLS) 2.0 m 6.2 Checklists for rigging work

5. Establishing the electrical connection;

à p. 6 - 30.

6. Adjust the angle position if necessary;

à p. 6 - 36.

7. Position the hoist rope;

8. Reeve the hook block.;

à p. 6 - 31.

à Betriebsanleitung GMK4100L-1.

9. Mount the lifting limit switch and attach the lifting limit switch weight: p. 6 - 34, Betriebsanleitung GMK4100L-1.

à à

10. Mount the anemometer and if necessary the air traffic control light; p. 6 - 34.

à

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6-9

Heavy load lattice extension (SLS) 2.0 m 6.2 Checklists for rigging work

11. If necessary, mount the camera;

à p. 6 - 35.

12. Check the horizontal alignment of the truck crane and correct it if necessary; Betriebsanleitung GMK4100L-1.

à

13. Enter the current rigging mode with the rigged heavy load lattice extension; p. 6 - 37.

à

à p. 6 - 32.

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14. Enter the current reeving;

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Heavy load lattice extension (SLS) 2.0 m 6.2 Checklists for rigging work

6.2.3

CHECKLIST: SLS 2.0 m installation into the transport position

H

This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references.

Observe the warnings and safety instructions there.

1. Prerequisite

à

– The truck crane is supported on outriggers; Betriebsanleitung GMK4100L-1.

– The appropriate counterweight for the crane operation must be rigged; Betriebsanleitung GMK4100L-1.

– The main boom must be completely retracted and lowered into horizontal position; Betriebsanleitung GMK4100L-1.

– An auxiliary crane must be available.

à

à

2. Check that section 6 is secured in the transport condition;

à p. 6 - 4.

3. Fasten slings to section 6 and attach a guide rope: Identification, p. 6 - 2

à à Transport dimensions and weights, p. 6 - 4 à Slinging points, p. 6 - 3.

4. Lift section 6 into position on the main boom and insert the pins; p. 6 - 23.

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à

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Heavy load lattice extension (SLS) 2.0 m 6.2 Checklists for rigging work

6.2.4

CHECKLIST: SLS 2.0 m removal from the working position

H

This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references.

Observe the warnings and safety instructions there.

1. Prerequisite – The truck crane is supported on outriggers; GMK4100L-1.

à Betriebsanleitung

– The appropriate counterweight for the crane operation must be Betriebsanleitung GMK4100L-1. rigged;

à

– The main boom must be completely retracted and lowered into Betriebsanleitung GMK4100L-1. horizontal position;

à

– An auxiliary crane must be available.

2. Remove the anemometer and if necessary the air traffic control light; p. 6 - 34.

à

3. If necessary, remove the camera;

à p. 6 - 35.

4. Remove the lifting limit switch weight and lifting limit switch; p. 6 - 34.

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à

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Heavy load lattice extension (SLS) 2.0 m 6.2 Checklists for rigging work

5. Unreeve the hoist rope and remove it from section 6;

6. Adjust to a 0° angle, if necessary;

à p. 6 - 31.

à p. 6 - 36.

7. Disconnect the electrical connection;

à p. 6 - 30.

8. Fasten slings to section 6 and attach a guide rope;

à p. 6 - 3.

9. Disconnect the connection between section 6 and the main boom; p. 6 - 24.

à

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10. Lift section 6 off the main boom and put it aside.

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s

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Heavy load lattice extension (SLS) 2.0 m 6.2 Checklists for rigging work

11. Reeve the hoist rope onto the main boom head, or roll it on to the drum; Betriebsanleitung GMK4100L-1.

à

à p. 6 - 4.

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12. Secure section 6 in the transport condition;

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Heavy load lattice extension (SLS) 2.0 m 6.2 Checklists for rigging work

6.2.5

CHECKLIST: Removing the SLS 2.0 m – from the transport position

H

This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references.

Observe the warnings and safety instructions there.

1. Prerequisite – The truck crane is supported on outriggers; GMK4100L-1.

à Betriebsanleitung

– The appropriate counterweight for the crane operation must be rigged; Betriebsanleitung GMK4100L-1.

à

– Section 6 must be folded up against the side of the main boom.

– An auxiliary crane must be available.

2. Fasten slings to section 6 and attach a guide rope;

à p. 6 - 3.

3. Disconnect the connection between section 6 and the main boom; p. 6 - 23.

à

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4. Lift section 6 off the main boom and put it aside.

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Heavy load lattice extension (SLS) 2.0 m 6.2 Checklists for rigging work

à p. 6 - 4.

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5. Secure section 6 in the transport condition;

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Heavy load lattice extension (SLS) 2.0 m 6.2 Checklists for rigging work

6.2.6

CHECKLIST: SLS 2.0 m rigging into the working position

H

This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references.

Observe the warnings and safety instructions there.

1. Prerequisite – The truck crane is supported on outriggers; GMK4100L-1.

à Betriebsanleitung

– The appropriate counterweight for the crane operation must be Betriebsanleitung GMK4100L-1. rigged;

à

2. Fasten the guide rope to section 6;

à p. 6 - 3.

3. Move section 6 into the working position;

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4. Adjust the angle position if necessary;

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à p. 6 - 26.

à p. 6 - 36.

s 6 - 17

Heavy load lattice extension (SLS) 2.0 m 6.2 Checklists for rigging work

5. Position the hoist rope;

6. Reeve the hook block.;

à p. 6 - 31.

à Betriebsanleitung GMK4100L-1.

7. Establishing the electrical connection;

à p. 6 - 30.

8. Mount the lifting limit switch and attach the lifting limit switch weight: p. 6 - 34, Betriebsanleitung GMK4100L-1.

à à

9. Mount the anemometer and if necessary the air traffic control light; p. 6 - 34.

à

à p. 6 - 35.

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10. If necessary, mount the camera;

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Heavy load lattice extension (SLS) 2.0 m 6.2 Checklists for rigging work

11. Check the horizontal alignment of the truck crane and correct it if necessary; Betriebsanleitung GMK4100L-1.

à

12. Enter the current rigging mode with the rigged heavy load lattice extension; p. 6 - 37.

à

à p. 6 - 32.

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13. Enter the current reeving;

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Heavy load lattice extension (SLS) 2.0 m 6.2 Checklists for rigging work

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Heavy load lattice extension (SLS) 2.0 m 6.2 Checklists for rigging work

6.2.7

CHECKLIST: SLS 2.0 m rigging into the transport position

H

This checklist is not equivalent to the complete operating instructions.

There are accompanying operating instructions which are indicated by cross-references.

Observe the warnings and safety instructions there!

1. Prerequisite – The truck crane is supported on outriggers; GMK4100L-1.

à Betriebsanleitung

– The appropriate counterweight for the crane operation must be Betriebsanleitung GMK4100L-1. rigged;

à

– The main boom must be completely retracted and lowered into Betriebsanleitung GMK4100L-1. horizontal position;

à

2. Remove the anemometer and if necessary the air traffic control light; p. 6 - 34.

à

3. If necessary, remove the camera;

à p. 6 - 35.

4. Remove the lifting limit switch weight and lifting limit switch; p. 6 - 34.

à

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Heavy load lattice extension (SLS) 2.0 m 6.2 Checklists for rigging work

5. Disconnect the electrical connection;

à p. 6 - 30.

6. Unreeve the hoist rope and remove it from section 6;

7. Adjust to a 0° angle, if necessary;

à p. 6 - 31.

à p. 6 - 36.

8. Fasten the guide rope to section 6;

à p. 6 - 3.

9. Move section 6 into the transport position;

à p. 6 - 28.

10. Reeve the hoist rope onto the main boom head, or roll it on to the drum; Betriebsanleitung GMK4100L-1.

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à

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Heavy load lattice extension (SLS) 2.0 m 6.3 Rigging work

6.3

Rigging work

6.3.1

Installing/removing section 6 on/from the main boom

Installing

– Section 6 must be attached to an auxiliary crane.

– A guide rope must be attached.

In the working position

• Align the connecting points (1).

• Remove the pins (2) from the clamps (3) and insert them into the connecting points (1).

• Secure the pins.

• Disconnect the guide rope and the lifting gear.

• If necessary, set the 40° angle; à p. 6 - 36.

• Remove the chain hoist; à p. 6 - 36.

• Position the hoist rope if necessary;

à p. 6 - 31.

Into the transport position

• Align the connecting points (1).

• Remove the pins (2) from the clamps (3) and insert them into the connecting points (1).

• Secure the pins.

• Disconnect the guide rope and the lifting

s

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gear.

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Heavy load lattice extension (SLS) 2.0 m 6.3 Rigging work

Removing

From the working position

• If necessary, remove the hoist rope;

à p. 6 - 31.

• If necessary, set the 0° angle; à p. 6 - 36.

• Sling the heavy load lattice extension to an auxiliary crane.

• Attach a guide rope.

• Remove the pins (2) from the connecting points (1) and insert them into the clamps (3).

• Secure the pins.

• Lift the heavy load lattice extension from the main boom.

• Set the heavy load lattice extension down on a suitable base.

• Disconnect the guide rope and the lifting

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gear.

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Heavy load lattice extension (SLS) 2.0 m 6.3 Rigging work

From the transport position

• Sling the heavy load lattice extension with an auxiliary crane.

• Attach a guide rope.

• Remove the pins (2) from the connecting points (1).

• Insert the pins into the clamps (3).

• Secure the pins.

• Lift the heavy load lattice extension from the main boom.

• Set the heavy load lattice extension down on a suitable base.

• Disconnect the guide rope and the lifting

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gear.

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Heavy load lattice extension (SLS) 2.0 m 6.3 Rigging work

6.3.2

Moving section 6 into the working position/transport position

In working position

G

Risk of accidents due to the heavy load lattice extension swinging of its own accord!

Always secure the heavy load lattice extension with a guide rope before disconnecting any connections.

This will prevent the swing-away lattice from swinging around of its own accord and causing injury to you or other persons.

• Attach a guide rope.

• Secure the heavy load lattice extension using the guide rope to prevent it swinging on its own.

• Remove the pin (2) from the connecting point (1).

• Insert the pin into the clamp (3).

• Secure the pin.

• Swing the heavy load lattice extension until the connecting points (1) are aligned.

• Remove the pins (2) from the clamps (3) and insert them into the connecting points (1).

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• Secure the pins.

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Heavy load lattice extension (SLS) 2.0 m 6.3 Rigging work

• Remove the pins (2) from the connecting points (1).

• Insert the pins into the clamps (3).

• Secure the pins.

• Swing the heavy load lattice extension until the connecting points (2) are aligned.

• Remove the pins (1) from the clamps (3).

• Insert the pins into the connecting points.

• Secure the pins.

• Remove the guide rope.

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Heavy load lattice extension (SLS) 2.0 m 6.3 Rigging work

In transport position

G

Risk of accidents due to the heavy load lattice extension swinging of its own accord!

Always secure the heavy load lattice extension with a guide rope before disconnecting any connections.

This will prevent the swing-away lattice from swinging around of its own accord and causing injury to you or other persons.

• If necessary, remove the hoist rope;

à p. 6 - 31.

• If necessary, set the 0° angle; à p. 6 - 36.

• Attach a guide rope.

• Remove the pins (2) from the connecting points (1).

• Insert the pins into the clamps (3).

• Secure the pins.

• Swing the heavy load lattice extension until the connecting points (1) are aligned.

• Remove the pins (2) from the clamps (3).

• Insert the pins into the connecting points.

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• Secure the pins.

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Heavy load lattice extension (SLS) 2.0 m 6.3 Rigging work

• Remove the pins (2) from the connecting points (1).

• Insert the pins (2) in die into the clamps (3).

• Secure the pins.

• Swing the heavy load lattice extension until the connecting point (1) is aligned.

• Remove the pin (2) from the clamp (3).

• Insert the pin into the connecting point.

• Secure the pin.

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• Remove the guide rope.

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Heavy load lattice extension (SLS) 2.0 m 6.3 Rigging work

6.3.3

Connecting/disconnecting the electrical connections – section 6/main boom

Establishing

• Remove the cable from the clamps (3).

• Insert the plug (2) in the socket (1).

• Fasten the cable to the clamps (3) so that it will not be damaged during crane operation.

Disconnecting

• Remove the plug (2) from the socket (1).

• Cover the socket (1) with the cap.

• Fasten the cable to the clamps so the cable

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and plug will not be damaged during crane operation.

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Heavy load lattice extension (SLS) 2.0 m 6.3 Rigging work

6.3.4

G

Positioning/removing the hoist rope – section 6 Risk of accidents due to falling parts!

Always secure the sheaves and rods with retaining pins.

This prevents sections coming loose, falling out and causing injuries.

Positioning the hoist rope

• Remove the rods (3).

• Guide the hoist rope over the sheaves (1) and (2).

• Insert the rods (3).

• Secure the rods.

• Reeve the hoist rope; à p. 6 - 32.

Removing the hoist rope

• Unreeve the hoist rope.

• Remove the rods (3).

• Remove the hoist rope from the sheaves (2) and (1).

• Insert the rods (3).

• Secure the rods.

• Reeve the hoist rope on the main boom;

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à Betriebsanleitung GMK 4100L-1.

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Heavy load lattice extension (SLS) 2.0 m 6.3 Rigging work

6.3.5

Possible reeving methods on the heavy load lattice extension 3 sheave hook block Reeving A

4-fall

B

3-fall

1 sheave hook block Reeving 3-fall

B

2-fall

C

1-fall

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A

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Heavy load lattice extension (SLS) 2.0 m 6.3 Rigging work

Hook tackle Reeving A

1-fall

The rope end fitting is fastened to the fixed point (1) for 2-fall, 4-fall, 6-fall reevings, etc.

à Betriebsanleitung GMK 4100L-1.

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Reeve the hoist rope;

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Heavy load lattice extension (SLS) 2.0 m 6.3 Rigging work

6.3.6

Installing/removing the lifting limit switch and anemometer

Lifting limit switch

If only a single lifting limit switch is available you must use the lifting limit Betriebsanleitung GMK4100L-1. switch belonging to the main boom;

à

If several lifting limit switches are available, all those lifting limit switches on the main boom from which no lifting limit switch weight is suspended must be overridden; Betriebsanleitung GMK4100L-1.

à

Installation – After separate transport

• Insert the lifting limit switch into the clamp (3) and secure it.

• Insert the plug (2) in the socket (1).

– After transport on the auxiliary singlesheave boom top

• Insert the plug (2) in the socket (1).

• Lay the cable so that it will not be damaged during crane operation.

• Install the lifting limit switch weight and lay

à Operating

it around the hoist rope; instructions GMK 4100L-1.

Removing

• Remove the lifting limit switch weight;

à Betriebsanleitung GMK4100L-1.

• Take the plug (2) out of the socket (1) and close the socket with the cap.

– For separate transport

• Remove the lifting limit switch (4) from the holder (3).

– For transport on the auxiliary single-sheave boom top

• Lay the cable so that it will not be damaged

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during crane operation.

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Heavy load lattice extension (SLS) 2.0 m 6.3 Rigging work

Anemometer

Installing and removing You must install the anemometer on the main boom for operation with the auxiliary single-sheave boom top.

For transportation you must take off the anemometer.

It is installed and removed in the same way as for working with the main boom; Operating instructionsGMK 4100L-1.

à

G 6.3.7

Risk of damage during transport!

Before transport, remove the anemometer.

This prevents the anemometer being damaged by sudden air currents.

Installing/removing the camera Installing and removing You can mount the camera on the main boom for operation with the heavy load lattice extension.

For transportation you must remove the camera.

It is installed and removed in the same way as for working with the main boom; Operating instructionsGMK 4100L-1.

à

à Betriebsanleitung GMK4100L-1.

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Operating the camera;

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Heavy load lattice extension (SLS) 2.0 m 6.3 Rigging work

6.3.8

G

Setting the angle Risk of accidents due to the heavy load lattice extension folding down!

During removal of the chain hoist, either the pin for the 0° inclination position or the pin for the 40° inclination position must be plugged in. This prevents the heavy load lattice extension folding down in an uncontrolled manner and injuring or killing you or others standing nearby.

• Attach the chain hoist supplied (2) at the slinging points (1) and (3).

• Use the chain hoist to relieve the load on the pins (5).

For a 0° inclination The heavy load lattice extension is inclined at 40°.

• Lift the heavy load lattice extension right up to the stop.

• Remove the pin (5) from the clamp (6).

• Insert the pin (5) into the connecting point (4).

• Secure the pin.

• Detach the chain hoist (2) from the attachment points (1) and (3).

• Safely stow away the chain hoist.

For a 40° inclination The heavy load lattice extension is inclined at 0°.

• Lift the heavy load lattice extension slightly with the chain hoist.

• Remove the pin (5) from connecting point (4) and insert it into the clamp (6).

• Secure the pin (5).

• Lower the heavy load lattice extension down to the stop.

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• Loosen the chain hoist.

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Heavy load lattice extension (SLS) 2.0 m 6.4 Operating the heavy load lattice extension

6.4

Operating the heavy load lattice extension The raising, lowering, slewing, derricking and telescoping movements of the main boom are carried out in the same way as when operating with the main boom. This section only contains information that you will need for a rigged or folded heavy load lattice extension.

6.4.1

Setting the RCL

Input

• Enter the current rigging mode for operation with the heavy load lattice extension. Use either the corresponding RCL code in accordance with the Lifting capacity table (1) or via individual components (2).

When you input the current rigging mode for the individual components you must also input – the length of the heavy load lattice extension (1) and – the angle of the heavy load lattice extension (2).

• Input the current reeving on the heavy load lattice extension for the hoist whose hoist rope is reeved on the heavy load lattice extension into the RCL.

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• Confirm the entry.

H

The lifting capacity for the RCL code is enabled once the telescopic sections are locked.

Lattice extension operating manual GMK 4100L-1

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Heavy load lattice extension (SLS) 2.0 m 6.4 Operating the heavy load lattice extension

Shutdown

Operation with the heavy load lattice extension is monitored by the RCL. When operating with the heavy load lattice extension, RCL shutdowns may occur for the same reasons as when operating with the main boom; Betriebsanleitung GMK4100L-1.

à

In certain rigging modes, the RCL shuts down when lifting loads that are lighter than the maximum load bearing capacity specified in the lifting capacity table .

– During operation with the heavy load lattice extension If a hook block (3) is reeved at the main boom, then the displayed current load (1) takes the following into consideration: – the weight of the lifted load (2) and – the weight of the hook block (3).

– During main boom operation If a heavy load lattice extension (4) is installed, then the displayed current load (1) takes the following into consideration: – the weight of the lifted load (2) and – the weight of the heavy load lattice extension (4)and – the weight of the hook block (3) at the heavy load lattice extension.

à

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H

The lifting capacity tables contain information for operations planning specifying the values which must be subtracted from the specified maximum load bearing capacities for certain rigging modes; Remarks about working with the heavy load lattice extension.

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Heavy load lattice extension (SLS) 2.0 m 6.4 Operating the heavy load lattice extension

6.4.2

Derricking, telescoping the main boom

Slewing range of 360°

G

Risk of accidents if the RCL is overridden!

Do not override the RCL when lowering the boom into horizontal position.

If the RCL is overridden, the crane operation will not be monitored and the truck crane will overturn if it moves outside of the permissible working range.

The requirements that must be satisfied before raising, lowering and telescoping the main boom with a rigged heavy load lattice extension are permitted, for a slewing range of 360° are monitored by the RCL; Betriebsanleitung GMK 4100L-1.

à

If the main boom is set to a steep angle and if the heavy load lattice extension is at 0°, the hook block may hit the main boom. When the minimum permitted working radius has been reached, the RCL will prevent the boom being raised further.

6.4.3

G

Procedure if permissible wind speeds are exceeded Risk of accidents at excessively high wind speeds!

If the current wind speed is higher than the maximum permissible wind speed, cease crane operation immediately and set up the corresponding rigging mode.

This will prevent the truck crane overturning due to overload.

• Prior to and during crane operation, check whether the current wind speed is lower than the maximum permissible wind speed.

• Make sure that you follow the instructions for checking the wind speed;

à Betriebsanleitung GMK 4100L-1.

If the maximum permissible wind speed is exceeded An automatic shutdown does not occur if the maximum permissible wind speed is exceeded.

• Immediately cease crane operation.

• Put the truck crane into the rigging mode specified for the current wind 07.11.2018

speed in the lifting capacity table.

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Heavy load lattice extension (SLS) 2.0 m 6.4 Operating the heavy load lattice extension

6.4.4

Instructions for turning loads over

à Turning loads over, p. 8 - 1.

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Notes on two-hook operation;

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Heavy load lattice extension (SLS) 2.0 m 6.5 Maintenance

6.5

Maintenance

H 6.5.1

If the lattice extension has been in storage for an extended period of time, perform maintenance on it, at the very latest when it is next used.

Maintenance plan M 1

M1

Maintenance work on the LATTICE EXTENSION: Monthly/after about 100 oper. hrs.

Heavy load lattice extension

à p. 6 - 42

– Lubricate the pins

6.5.2

Maintenance plan M 3

M3

Maintenance work on the LATTICE EXTENSION: Every three months/after 250 oper. hrs.

Heavy load lattice extension

à p. 6 - 42

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– Check the sheaves

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6 - 41

Heavy load lattice extension (SLS) 2.0 m 6.5 Maintenance

6.5.3

Description of maintenance work Grease 1) Grease 1)

Designation to DIN 51502

Specifications Classification

GROVE Section no.1)

KP - 1K - 50

DIN 51825

03233369

à Wartungsanleitung Lubricate the pins – section 6

• Grease the pins (1).

Check the sheaves – section 6

• Check the deflection sheave (3) and head sheaves (2) for damage, wear, mobility and heavy soiling.

• Have damaged, worn, stiff or extremely soiled

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sheaves replaced by Manitowoc Crane Care or an authorised GROVE dealer or your repair crew.

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Lattice extension operating manual GMK 4100L-1

Auxiliary single-sheave boom top 7.1 Operations planning

7

Auxiliary single-sheave boom top

7.1

Operations planning

7.1.1

Identification and slinging points

G G

Risk of accidents if auxiliary single-sheave boom tops are interchanged!

Install only a auxiliary single-sheave boom top that belongs to the crane.

No other auxiliary single-sheave boom tops may be installed.

Risk of accidents if used improperly!

Only fit slings to the auxiliary single-sheave boom top at the slinging points provided. Use only lifting gear and joining elements of sufficient load bearing capacity.

Identification The crane and the corresponding auxiliary single-sheave boom top must be labelled with the same serial number (4).

Slinging points The fixed slinging point (1) is marked with a sticker (2).

The sticker (3) gives data on the weight and the necessary lifting gear.

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The rope attachment point (5) serves as the slinging point for the guide rope.

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7-1

Auxiliary single-sheave boom top 7.1 Operations planning

7.1.2

7.1.3

S G

Transport dimensions and weights

Section

Length x width x height in m1)

Weight in kg

Auxiliary singlesheave boom top

0.70 x 0.80 x 1.50

100

Transport condition Risk of damage to the auxiliary single-sheave boom top!

Always secure the auxiliary single-sheave boom top by tying it down with suitable belts during transportation on a separate vehicle. This prevents the auxiliary single-sheave boom top tipping over and becoming damaged during transportation.

Risk of injury if the pins are not secured!

Before transport make sure that all pins are secured in the clamps with retaining pins. Secure any pins that are not secure.

This way you prevent the pins from falling down while driving and injuring or even killing other persons.

• Check that the auxiliary single-sheave boom top is in the transport condition or establish this now, if necessary: – All pins (1) must be secured in the connecting points.

– The auxiliary single-sheave boom top must be secured to a suitable support.

– The lifting limit switch must be plugged into the holder (5) and secured.

– The lifting limit switch connecting cable must be wound on to the holder (4) and the plug inserted into the socket (3).

7-2

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– The lifting limit switch weight must be plugged into the holder (2) and secured.

Auxiliary single-sheave boom top 7.2 Rigging work

7.2

Rigging work

G 7.2.1

Danger of hands and fingers being crushed!

Keep hands and fingers away from the swinging auxiliary single-sheave boom top. Hands or fingers can be crushed at the connecting points.

Moving the auxiliary single-sheave boom top into the working position After transport on a separate vehicle

• Sling the auxiliary single-sheave boom top to an auxiliary crane;

à p. 9 - 1.

• Attach a guide rope.

• Remove the pins (1) from the connecting points (2).

• Lift the auxiliary single-sheave boom top in front of the main boom so that the connection points (2) are aligned.

• Insert the pins (1) into the connecting points.

• Secure the pins.

• Disconnect the guide rope and the lifting gear.

• Position the hoist rope if necessary;

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à p. 9 - 11.

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s 7-3

Auxiliary single-sheave boom top 7.2 Rigging work

After transport on the main boom

• Attach a guide rope.

• Remove the pin (3) from the connecting point (4).

• Remove the pin (1) from the connecting point (2).

• Swing the auxiliary single-sheave boom top until the connecting points (2) and (4) are aligned.

• Insert the pins (1) and (3) into the connecting points (2) and (4).

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• Secure the pins.

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Auxiliary single-sheave boom top 7.2 Rigging work

• Remove the pin (1) from the connecting point (2).

• Swing the auxiliary single-sheave boom top until the connecting point (2) is aligned.

• Insert the pin (1) into the connecting point (2).

• Secure the pin.

• Remove the guide rope.

• Position the hoist rope if necessary;

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à p. 9 - 11.

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7-5

Auxiliary single-sheave boom top 7.2 Rigging work

7.2.2

Moving the auxiliary single-sheave boom top into the transport position For transport on a separate vehicle

• Sling the auxiliary single-sheave boom top to an auxiliary crane;

à p. 9 - 1.

• Attach a guide rope.

• Remove the pins (1) from the connecting points (2).

• Lift the auxiliary single-sheave boom top from the main boom.

• Insert the pins (1) in into the connecting points (2).

• Secure the pins.

• Disconnect the guide rope and the lifting

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gear.

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Auxiliary single-sheave boom top 7.2 Rigging work

For transport on the main boom

• If necessary, remove the hoist rope;

à p. 9 - 11.

• Attach a guide rope.

• Remove the pin (1) from the connecting point (2).

• Swing the auxiliary single-sheave boom top until the connecting point (2) is aligned.

• Insert the pin (1) into the connecting point (2).

• Secure the pin.

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7-7

Auxiliary single-sheave boom top 7.2 Rigging work

• Remove the pins (1) and (3) from the connecting points (2) and (4).

• Swing the auxiliary single-sheave boom top until the connecting point (2) is aligned.

• Insert the pin (1) into the connecting point (2).

• Secure the pin.

• Insert the pin (3) into the connecting point (4).

• Secure the pin.

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• Remove the guide rope.

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Auxiliary single-sheave boom top 7.2 Rigging work

7.2.3

Installing/removing a folded up auxiliary single-sheave boom top Installing

• Sling the auxiliary single-sheave boom top to an auxiliary crane;

à p. 9 - 1.

• Attach a guide rope.

• Remove the pins (1) from the connecting points (2).

• Insert the pin (4) into the connecting point (3).

• Lift the auxiliary single-sheave boom top in front of the main boom so that the connection points (2) are aligned.

• Insert the pins (1) in into the connecting points (2).

• Secure the pins.

• Disconnect the guide rope and the lifting gear.

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7-9

Auxiliary single-sheave boom top 7.2 Rigging work

• Removing • Sling the auxiliary single-sheave boom top to an auxiliary crane;

à p. 9 - 1.

• Attach a guide rope.

• Remove the pins (1) from the connecting points (2).

• Lift the auxiliary single-sheave boom top from the main boom.

• Insert the pins (1) in into the connecting points (2).

• Secure the pins.

• Disconnect the guide rope and the lifting

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gear.

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Auxiliary single-sheave boom top 7.2 Rigging work

7.2.4

G

Attaching and removing the hoist rope Risk of accidents due to falling parts!

Always secure the sheaves and rods with retaining pins.

This prevents sections coming loose, falling out and causing injuries.

Fitting

• Remove the rods (3) and sheaves (4).

• Guide the hoist rope over the sheaves (1) and (2).

• Insert the rods (3) and fasten the guide sheaves (4).

• Secure the rods.

Removing

• Remove the rods (3) and sheaves (4).

• Remove the hoist rope from the sheaves (2) and (1).

• Insert the rods (3) and fasten the guide sheaves (4).

• Secure the rods.

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7 - 11

Auxiliary single-sheave boom top 7.2 Rigging work

Possible reeving methods

• Attach the hook tackle or reeve the hook block.

• With 2-fall reeving, fasten the rope end fitting to the fixed point (1).

1-sheave hook block Reeving A

2-fall

B

1-fall

Hook tackle Reeving C

1-fall

1 sheave hook block and hook tackle Reeving 1-fall

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A

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Auxiliary single-sheave boom top 7.2 Rigging work

7.2.5

Installing/removing the lifting limit switch and anemometer

Lifting limit switch

If only a single lifting limit switch is available you must use the lifting limit Betriebsanleitung GMK4100L-1. switch belonging to the main boom;

à

If several lifting limit switches are available, all those lifting limit switches on the main boom from which no lifting limit switch weight is suspended must be overridden; Betriebsanleitung GMK4100L-1.

à

Installation After separate transport

• Fit the lifting limit switch (4) on the clamp (3) and secure it.

• Insert the plug (2) in the socket (1).

• Fasten the cable in the clamp (6). Fasten the cable so that it does not sag during crane operation and thus might be damaged.

• Install the lifting limit switch weight (5) and lay it around the hoist rope; manual GMK 4100L-1.

à Operating

After transport on the auxiliary single-sheave boom top

• Remove the lifting limit switch weight (5) from the clamp (8).

• Remove the plug (2) from the dummy socket (7).

• Insert the plug (2) in the socket (1).

• Fasten the cable in the clamp (6). Fasten the cable so that it does not sag during crane operation and thus might be damaged.

• Install the lifting limit switch weight (5) and lay it around the hoist rope; manual GMK 4100L-1.

à Operating

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7 - 13

Auxiliary single-sheave boom top 7.2 Rigging work

Removing For separate transport

• Remove the lifting limit switch weight (5);

à Betriebsanleitung GMK4100L-1.

• Remove the lifting limit switch (4) from the holder (3).

• Take the plug (2) out of the socket (1) and close the socket with the cap.

• Stow the lifting limit switch so that it is safe in traffic, or install it on the main boom; Betriebsanleitung GMK4100L-1.

à

For transport on the auxiliary single-sheave boom top

• Fit the lifting limit switch weight (5) on the clamp (8) and secure it.

• Take the plug (2) out of the socket (1) and close the socket with the cap.

• Insert the plug (2) into the dummy socket (7).

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• Fasten the cable in the clamp (6).

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Lattice extension operating manual GMK 4100L-1

Auxiliary single-sheave boom top 7.2 Rigging work

Anemometer

Installing and removing You must install the anemometer on the main boom for operation with the auxiliary single-sheave boom top.

For transportation you must take off the anemometer.

It is installed and removed in the same way as for working with the main boom; Operating instructions GMK 4100L-1.

à

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G

Risk of damage during transport!

Before transport, remove the anemometer.

This prevents the anemometer being damaged by sudden air currents.

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7 - 15

Auxiliary single-sheave boom top 7.2 Rigging work

7.2.6

Installing/removing the camera Installing and removing You can mount the camera on the main boom for operation with the auxiliary single-sheave boom top.

For transportation you must remove the camera.

It is installed and removed in the same way as for working with the main Operating instructions GMK 4100L-1. boom;

à

à Betriebsanleitung GMK4100L-1.

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Operating the camera;

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Auxiliary single-sheave boom top 7.3 Operation with the auxiliary single-sheave boom top

7.3

Operation with the auxiliary single-sheave boom top The raising, lowering, slewing, derricking and telescoping movements of the main boom are carried out in the same way as when operating with the main boom. This section only contains information that you will need for a rigged or folded up auxiliary single-sheave boom top.

7.3.1

Setting the RCL

Input

• Input the current rigging mode for operation with the main boom into the RCL. Use either the corresponding RCL code in accordance with the Lifting capacity table (1) or via individual components (2).

• Enter the current reeving on the swing-away lattice for the hoisting gear whose hoist rope is reeved on the swing-away lattice into the RCL.

• Confirm the entry.

H

The lifting capacity for the RCL code is enabled once the telescopic sections are locked.

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7 - 17

Auxiliary single-sheave boom top 7.3 Operation with the auxiliary single-sheave boom top

Shutdown

Operation with the auxiliary single-sheave boom top is monitored by the RCL. When operating with the auxiliary single-sheave boom top, RCL shutdowns may occur for the same reasons as when operating with the main boom; Betriebsanleitung GMK4100L-1.

à

In certain rigging modes, the RCL shuts down when lifting loads that are lighter than the maximum load bearing capacity specified in the lifting capacity table.

– During operation with the auxiliary single-sheave boom top If a hook block (3) is reeved at the main boom, then the displayed current load (1) takes the following into consideration: – the weight of the lifted load (2) and – the weight of the hook block (3).

– During main boom operation If a auxiliary single-sheave boom top (4) is installed, then the displayed current load (1) takes the following into consideration: – the weight of the lifted load (2) and – the weight of the auxiliary single-sheave boom top (4) and

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– the weight of the hook block (3) on the auxiliary single-sheave boom top.

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Lattice extension operating manual GMK 4100L-1

Auxiliary single-sheave boom top 7.3 Operation with the auxiliary single-sheave boom top

7.3.2

G

Procedure if permissible wind speeds are exceeded Risk of accidents at excessively high wind speeds!

If the current wind speed is higher than the maximum permissible wind speed, cease crane operation immediately and set up the corresponding rigging mode.

This will prevent the truck crane overturning due to overload.

• Prior to and during crane operation, check whether the current wind speed is lower than the maximum permissible wind speed.

• Make sure that you follow the instructions for checking the wind speed;

à Tragfähigkeitstabelle and Betriebsanleitung GMK 4100L-1.

If the maximum permitted wind speed is exceeded: An automatic shutdown does not occur if the maximum permissible wind speed is exceeded.

• Immediately cease crane operation.

• Put the truck crane into the rigging mode specified for the current wind speed in the lifting capacity table.

7.3.3

Instructions for turning loads over

à Turning loads over, p. 10 - 1.

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Notes on two-hook operation;

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7 - 19

Auxiliary single-sheave boom top 7.3 Operation with the auxiliary single-sheave boom top

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Blank page

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Lattice extension operating manual GMK 4100L-1

Auxiliary single-sheave boom top 7.4 Maintenance

7.4

Maintenance

H 7.4.1

If the lattice extension has been in storage for an extended period of time, perform maintenance on it, at the very latest when it is next used.

Maintenance plan M 1

M1

Maintenance work on the LATTICE EXTENSION: Monthly/after about 100 oper. hrs.

Auxiliary single-sheave boom top

à p. 9 - 22

– Lubricating the pins

7.4.2

Maintenance plan M 3

M3

Maintenance work on the LATTICE EXTENSION: Every three months/after 250 oper. hrs.

Auxiliary single-sheave boom top

à p. 9 - 22

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– Check the sheaves

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7 - 21

Auxiliary single-sheave boom top 7.4 Maintenance

7.4.3

Description of maintenance work Grease 1) Grease 1)

Designation to DIN 51502

Specifications Classification

GROVE Section no.1)

KP - 1K - 50

DIN 51825

03233369

à Wartungsanleitung Lubricating the pins

• Grease the pins (1) and (2).

Check the sheaves

• Check the sheaves (3) for damage, wear, mobility and heavy soiling.

• Have damaged, worn, stiff or extremely soiled

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sheaves replaced by Manitowoc Crane Care or an authorised GROVE dealer or your repair crew.

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Lattice extension operating manual GMK 4100L-1

Turning loads over

8

Turning loads over Turning loads over is permitted only using – Swing-away lattice – Heavy load lattice extension (SLS) – Auxiliary single-sheave boom top.

G Prerequisites

Risk of accidents due to incorrect procedure!

Before turning loads, observe all the prerequisites specified in this section and proceed exactly as described. This way, you avoid accidents due to overload.

– The main hoist rope must be reeved on the main boom.

– The auxiliary hoist rope must be reeved on the lattice extension.

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– The main hoist rope must be reeved with at least the same number of falls as the auxiliary hoist rope.

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8-1

Turning loads over 8.1 Setting the RCL

8.1

Setting the RCL

Entering the reeving

Before lifting the load, you must enter the number of currently reeved falls for both hoists into the RCL, so that the data is immediately available should you subsequently wish to switch over to the main hoist after turning the load over.

Main hoist

• Select the symbol (1) and confirm your selection.

• Select the current reeved number of falls, for example, 3.

• Confirm the entry.

Auxiliary hoist

• Select the symbol (2) and confirm your entry.

• Select the current reeved number of falls, for example, 2.

• Confirm the entry.

Switching over to the auxiliary hoist

The load must first be lifted using the auxiliary hoist.

Turning a load over requires use of both hoists simultaneously. The RCL always uses the reeving data for the first hoist to be switched on.

• Switch off both hoists – symbols (1) and (2) are red.

• Switch on the auxiliary hoist – symbol (2) is green.

• Switch on the main hoist – symbol (1) is green.

• Enter the RCL code corresponding to the rigging mode according to the lifting capacity table for the rigged lattice extension.

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The RCL now takes into account: – The reeving for the auxiliary hoist and – The lifting capacity tables for the lattice extension.

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Turning loads over 8.2 Turning a load over

8.2

Turning a load over

H

Before turning a load over, check that this procedure is in accordance with the regulations in the country in which you are working.

• Check that all the prerequisites have been met;

à Prerequisites, p. 10 - 1.

• Check that the RCL is correctly set;

à Prerequisites, p. 10 - 1.

G H

Risk of accidents due to overloading!

Ensure that the RCL is set for operation with the lattice extension during the entire procedure and move the load only at minimum speed.

In this way you prevent the crane becoming overloaded.

As soon as the load is on two hooks, there will be slight deviations in the Current load display. However, these deviations are on the safe side with regard to RCL shutdown.

Turning a load over is performed the same way, irrespective of which of the permitted lattice extensions is used. In this section the illustration shows a lattice extension, which is used to symbolically represent all the other options.

• (A) – Lift the load completely with the lattice extension.

• (B) – Sling the load additionally at the main boom.

• (C) – Lift the load with the main hoist till both the slinging points are at the same height.

• (D) – Lower the load with the auxiliary hoist until the load is completely suspended from the main hoist rope.

• Detach the auxiliary hoist rope from the load.

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8-3

Turning loads over 8.2 Turning a load over

Switching over to the main hoist • Switch the auxiliary hoist off – the RCL will now use the reeving data for the main hoist.

• After the load has been set down, enter the RCL code appropriate to the

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boom system that will be used for the next lift.

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Driving with a rigged crane 9.1 Safety instructions

9

Driving with a rigged crane

9.1

Safety instructions

Risk of overturning by slewing superstructure!

When driving the rigged truck crane, the slewing gear must be switched off – slewing gear brake engaged.

Risk of accidents when driving with a lifted load!

Driving the truck crane with a load lifted is prohibited. Always set down the load prior to driving the truck crane and secure the hook block so it cannot swing.

Danger of tipping when driving the rigged truck crane!

Driving with a rigged truck crane is an operating mode which must be carried out with the utmost care. Be sure to always observe all specifications and safety instructions in the Betriebsanleitung GMK 4100L-1.

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G G G G

Risk of accidents due to partially obstructed view of the truck crane!

When driving the truck crane, always stay in visual or radio contact with a banksman who can observe the parts you are unable to see, for example, the raised main boom in the 0° to the rear position.

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9-1

Driving with a rigged crane 9.2 Driving distance

9.2

Driving distance The driving distance to be driven must be level. The level adjustment system cannot compensate for uneven surfaces.

The entire driving distance must be level. The rigging modes and axle loads specified in this chapter only for routes which are free of inclines in longitudinal and lateral direction.

The ground must be stable enough to bear the axle loads.

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If the surface pressure of the tyres exceeds the permissible load on the ground, the surface area of the tyres must be increased by laying stable material (e.g. wooden planks) on it.

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Driving with a rigged crane 9.3 Permissible rigging modes and axle loads

9.3

Permissible rigging modes and axle loads Depending on the rigged counterweight and lattice extension, you must bring the superstructure, the main boom and rigged into certain positions so that the permissible axle loads are not exceeded.

S

Risk of damage to the axle lines!

Move the superstructure, the main boom and the lattice extension into the specified positions only. This prevents excessive strain on the axle lines.

• Enter the RCL code for the actual rigging mode and actual outrigger span of the truck crane in accordance with the Lifting capacity table.

G

Risk of accidents if the RCL is overridden!

Always enter the RCL code for the current rigging mode. The specified positions are within the monitored operating ranges.

If the RCL is overridden, the truck crane may overturn even if you move it into the positions specified.

• Bring the superstructure, the main boom and the lattice extension into the position specified for the rigged counterweight in the following table.

• Tie down the hook block so that it cannot swing around.

Notes on the tables

H

The axle loads specified in the following tables refer to a driving mode with the basic unit.

Note on the specified angle ranges The specified maximum axle load is only reached at the limits of the listed angle range for the main boom, e.g. at 20° or 70°. If the maximum axle load is reached at the front, it will be below the maximum value at the rear and vice versa.

The axle loads are below the specified maximum axle loads within the listed angle range.

The following applies to the footnotes in the table: 1)

Display, slewing angle 0°

Front:

Display, slewing angle 180°

Front:

Each on the 1st and 2nd axle lines

Rear

Each on the 3rd and 4th axle lines

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2)

Rear:

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9-3

Driving with a rigged crane 9.3 Permissible rigging modes and axle loads

9.3.1

Swing-away lattice

Swing-away lattice 1.7 + 7.7 m

All axle loads specified apply to a reeved 1-sheave hook block, weight 450 kg.

The axle loads are applicable for all approved tyres; GMK4100L-1.

Counterweight in t

telescope status telescopic section I-II-III-IV-V-VI in %

à Betriebsanleitung

Main boom Lattice Superstrucangle extension ture in ° inclination position 1) in °

Maximum axle load 2) in t front

rear

0-0-0-0-0-0

40 - 75

0 - 40

front

14.5

15.5

0-0-0-0-0-0

60 - 82

0 - 40

rear

13.0

15.5

0-0-0-0-0-0

40 - 65

0 - 40

front

13.5

16.0

0-0-0-0-0-0

55 - 82

0 - 40

rear

14.5

16.5

0-0-0-0-0-0

40 - 60

0 - 40

front

13.0

16.0

0-0-0-0-0-0

50 - 82

0 - 40

rear

15.5

17.0

0-0-0-0-0-0

40 - 60

0 - 40

front

12.5

17.0

0-0-0-0-0-0

50 - 82

0 - 40

rear

16.0

17.0

0-0-0-0-0-0

45 - 55

0 - 40

front

12.0

17.5

0-0-0-0-0-0

45 - 82

0 - 40

rear

16.5

18.0

0-0-0-0-0-0

40 - 55

0 - 40

front

12.0

18.5

0-0-0-0-0-0

45 - 82

0 - 40

rear

17.0

18.0

0-0-0-0-0-0

40 - 50

0 - 40

front

11.0

19.0

0-0-0-0-0-0

40 - 82

0 - 40

rear

18.0

18.5

0-0-0-0-0-0

40 - 45

0 - 40

front

10.5

19.5

0-0-0-0-0-0

40 - 82

0 - 40

rear

19.0

19.0

50-0-0-0-0-0

40 - 55

0 - 40

front

14.5

19.5

0-0-0-0-0-0

40 - 82

0 - 40

rear

19.5

19.0

50-0-0-0-0-0

40 - 50

0 - 40

front

14.0

20.0

0-0-0-0-0-0

40 - 82

0 - 40

rear

21.0

19.0

50-0-0-0-0-0

40 - 45

0 - 40

front

13.0

20.5

0-0-0-0-0-0

40 - 80

0 - 40

rear

21.5

19.0

0.8

4.5

5.7

6.7

8.5

9.7

11.6

13.1

14.9

19.9

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17.4

Driving with a rigged crane 9.3 Permissible rigging modes and axle loads

Counterweight in t

telescope status telescopic section I-II-III-IV-V-VI in %

Main boom Lattice Superstrucangle extension ture in ° inclination position 1) in °

Maximum axle load 2) in t front

rear

50-0-0-0-0-0

45 - 45

0 - 40

front

12.5

22.0

0-0-0-0-0-0

40 - 80

0 - 40

rear

22.5

19.0

50-50-0-0-0-0

40 - 50

0 - 40

front

15.0

22.5

0-0-0-0-0-0

40 - 75

0 - 40

rear

22.5

19.0

50-50-0-0-0-0

40 - 50

0 - 40

front

14.5

22.5

0-0-0-0-0-0

45 - 75

0 - 40

rear

23.5

19.0

21.4

24.0

26.2 1), 2)

à Notes on the tables, p. 11 - 3

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9-5

Driving with a rigged crane 9.3 Permissible rigging modes and axle loads

Swing-away lattice 1.7 + 14.3 m

All axle loads specified apply to a reeved 1-sheave hook block, weight 450 kg.

The axle loads are applicable for all approved tyres; GMK4100L-1.

Counterweight in t

telescope status telescopic section I-II-III-IV-V-VI in %

à Betriebsanleitung

Main boom Lattice Superstrucangle extension ture in ° inclination position 1) in °

Maximum axle load 2) in t front

rear

0-0-0-0-0-0

45 - 75

0 - 40

front

15.0

15.5

0-0-0-0-0-0

65 - 82

0 - 40

rear

13.0

15.5

0-0-0-0-0-0

40 - 65

0 - 40

front

14.5

16.0

0-0-0-0-0-0

60 - 82

0 - 40

rear

14.5

16.5

0-0-0-0-0-0

40 - 65

0 - 40

front

14.5

17.0

0-0-0-0-0-0

60 - 82

0 - 40

rear

15.0

16.5

0-0-0-0-0-0

40 - 60

0 - 40

front

14.0

16.5

0-0-0-0-0-0

55 - 82

0 - 40

rear

15.5

17.5

0-0-0-0-0-0

40 - 60

0 - 40

front

13.5

18.0

0-0-0-0-0-0

55 - 82

0 - 40

rear

16.5

17.5

0-0-0-0-0-0

40 - 50

0 - 40

front

13.0

18.0

0-0-0-0-0-0

50 - 82

0 - 40

rear

17.0

18.5

0-0-0-0-0-0

40 - 50

0 - 40

front

12.5

18.5

0-0-0-0-0-0

50 - 82

0 - 40

rear

18.0

18.5

0-0-0-0-0-0

40 - 50

0 - 40

front

12.0

19.5

0-0-0-0-0-0

45 - 82

0 - 40

rear

18.5

19.5

50-0-0-0-0-0

40 - 55

0 - 40

front

16.0

18.5

0-0-0-0-0-0

40 - 82

0 - 40

rear

19.5

20.0

50-0-0-0-0-0

40 - 55

0 - 40

front

15.0

20.5

0-0-0-0-0-0

40 - 82

0 - 40

rear

21.0

20.0

50-0-0-0-0-0

40 - 50

0 - 40

front

14.5

21.0

0-0-0-0-0-0

40 - 82

0 - 40

rear

22.0

20.5

50-0-0-0-0-0

40 - 50

0 - 40

front

14.0

22.5

0-0-0-0-0-0

40 - 80

0 - 40

rear

22.0

20.5

0.8

4.5

5.7

6.7

8.5

9.7

11.6

13.1

14.9

17.4

21.4

9-6

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07.11.2018

19.9

Driving with a rigged crane 9.3 Permissible rigging modes and axle loads

Counterweight in t

telescope status telescopic section I-II-III-IV-V-VI in %

Main boom Lattice Superstrucangle extension ture in ° inclination position 1) in °

Maximum axle load 2) in t front

rear

50-50-0-0-0-0

40 - 55

0 - 40

front

16.5

23.5

0-0-0-0-0-0

40 - 75

0 - 40

rear

22.0

20.5

50-50-0-0-0-0

40 - 50

0 - 40

front

16.0

23.5

0-0-0-0-0-0

40 - 75

0 - 40

rear

23.5

20.5

24.0

26.2

à Notes on the tables, p. 11 - 3

07.11.2018

1), 2)

Lattice extension operating manual GMK 4100L-1

3 302 730 en

9-7

Driving with a rigged crane 9.3 Permissible rigging modes and axle loads

9.3.2

Boom extension

Boom extension 9.7 + 7.7 m

All axle loads specified apply to a reeved 1-sheave hook block, weight 450 kg.

The axle loads are applicable for all approved tyres; GMK4100L-1.

Counterweight in t

telescope status telescopic section I-II-III-IV-V-VI in %

à Betriebsanleitung

Main boom Lattice Superstrucangle extension ture in ° inclination position 1) in °

Maximum axle load 2) in t front

rear

0-0-0-0-0-0

45 - 75

0 - 40

front

15.5

15.0

0-0-0-0-0-0

65 - 82

0 - 40

rear

12.5

15.5

0-0-0-0-0-0

40 - 70

0 - 40

front

15.5

17.0

0-0-0-0-0-0

60 - 82

0 - 40

rear

14.5

17.0

0-0-0-0-0-0

40 - 65

0 - 40

front

15.0

16.5

0-0-0-0-0-0

60 - 82

0 - 40

rear

15.0

17.0

0-0-0-0-0-0

40 - 65

0 - 40

front

14.5

17.0

0-0-0-0-0-0

60 - 82

0 - 40

rear

15.5

17.0

0-0-0-0-0-0

40 - 60

0 - 40

front

14.0

17.5

0-0-0-0-0-0

55 - 82

0 - 40

rear

16.5

18.0

0-0-0-0-0-0

40 - 60

0 - 40

front

13.5

18.5

0-0-0-0-0-0

55 - 82

0 - 40

rear

17.0

18.0

0-0-0-0-0-0

40 - 55

0 - 40

front

13.0

19.0

0-0-0-0-0-0

50 - 82

0 - 40

rear

18.0

19.0

0-0-0-0-0-0

40 - 50

0 - 40

front

12.5

19.0

0-0-0-0-0-0

50 - 82

0 - 40

rear

18.5

19.0

0-0-0-0-0-0

40 - 50

0 - 40

front

12.0

20.5

0-0-0-0-0-0

45 - 82

0 - 40

rear

19.5

20.0

50-0-0-0-0-0

40 - 55

0 - 40

front

16.0

20.0

0-0-0-0-0-0

40 - 82

0 - 40

rear

20.5

21.0

50-0-0-0-0-0

45 - 55

0 - 40

front

15.0

22.0

0-0-0-0-0-0

40 - 82

0 - 40

rear

22.0

21.0

0.8

4.5

5.7

6.7

8.5

9.7

11.6

13.1

14.9

19.9

9-8

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Lattice extension operating manual GMK 4100L-1

07.11.2018

17.4

Driving with a rigged crane 9.3 Permissible rigging modes and axle loads

Counterweight in t

telescope status telescopic section I-II-III-IV-V-VI in %

Main boom Lattice Superstrucangle extension ture in ° inclination position 1) in °

Maximum axle load 2) in t front

rear

50-0-0-0-0-0

40 - 50

0 - 40

front

15.0

21.5

0-0-0-0-0-0

40 - 80

0 - 40

rear

22.0

21.0

50-50-0-0-0-0

40 - 55

0 - 40

front

17.5

22.5

0-0-0-0-0-0

40 - 80

0 - 40

rear

23.5

21.0

50-50-0-0-0-0

40 - 50

0 - 40

front

17.0

22.5

0-0-0-0-0-0

40 - 75

0 - 40

rear

23.0

21.0

21.4

24.0

26.2 1), 2)

à Notes on the tables, p. 11 - 3

07.11.2018

s

Lattice extension operating manual GMK 4100L-1

3 302 730 en

9-9

Driving with a rigged crane 9.3 Permissible rigging modes and axle loads

Boom extension 9.7 + 14.3 m

All axle loads specified apply to a reeved 1-sheave hook block, weight 450 kg.

The axle loads are applicable for all approved tyres; GMK4100L-1.

Counterweight in t

telescope status telescopic section I-II-III-IV-V-VI in %

à Betriebsanleitung

Main boom Lattice Superstrucangle extension ture in ° inclination position 1) in °

Maximum axle load 2) in t front

rear

0-0-0-0-0-0

55 - 75

0 - 40

front

15.0

15.0

0-0-0-0-0-0

70 - 82

0 - 40

rear

12.5

15.5

0-0-0-0-0-0

40 - 70

0 - 40

front

17.0

16.5

0-0-0-0-0-0

65 - 82

0 - 40

rear

14.5

17.0

0-0-0-0-0-0

40 - 70

0 - 40

front

16.5

17.5

0-0-0-0-0-0

65 - 82

0 - 40

rear

15.0

17.0

0-0-0-0-0-0

40 - 65

0 - 40

front

16.0

16.5

0-0-0-0-0-0

65 - 82

0 - 40

rear

15.5

17.0

0-0-0-0-0-0

40 - 65

0 - 40

front

15.5

18.0

0-0-0-0-0-0

60 - 82

0 - 40

rear

16.5

18.0

0-0-0-0-0-0

40 - 60

0 - 40

front

15.5

17.5

0-0-0-0-0-0

60 - 82

0 - 40

rear

17.0

18.0

0-0-0-0-0-0

40 - 60

0 - 40

front

14.5

19.5

0-0-0-0-0-0

55 - 82

0 - 40

rear

18.0

19.5

0-0-0-0-0-0

40 - 55

0 - 40

front

14.0

19.0

0-0-0-0-0-0

55 - 82

0 - 40

rear

18.5

19.5

0-0-0-0-0-0

40 - 50

0 - 40

front

13.5

19.5

0-0-0-0-0-0

55 - 82

0 - 40

rear

19.5

19.5

0-0-0-0-0-0

40 - 50

0 - 40

front

13.0

21.5

0-0-0-0-0-0

50 - 82

0 - 40

rear

20.5

20.5

50-0-0-0-0-0

40 - 55

0 - 40

front

17.0

21.0

0-0-0-0-0-0

45 - 82

0 - 40

rear

22.0

21.5

50-0-0-0-0-0

40 - 55

0 - 40

front

16.5

22.0

0-0-0-0-0-0

40 - 82

0 - 40

rear

22.5

22.5

0.8

4.5

5.7

6.7

8.5

9.7

11.6

13.1

14.9

17.4

21.4

9 - 10

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Lattice extension operating manual GMK 4100L-1

07.11.2018

19.9

Driving with a rigged crane 9.3 Permissible rigging modes and axle loads

Counterweight in t

telescope status telescopic section I-II-III-IV-V-VI in %

Main boom Lattice Superstrucangle extension ture in ° inclination position 1) in °

Maximum axle load 2) in t front

rear

50-0-0-0-0-0

40 - 50

0 - 40

front

15.5

22.5

0-0-0-0-0-0

40 - 80

0 - 40

rear

23.0

22.5

50-50-0-0-0-0

40 - 55

0 - 40

front

18.5

23.5

0-0-0-0-0-0

40 - 80

0 - 40

rear

24.0

22.5

24.0

26.2

à Notes on the tables, p. 11 - 3

07.11.2018

1), 2)

Lattice extension operating manual GMK 4100L-1

3 302 730 en

9 - 11

Driving with a rigged crane 9.3 Permissible rigging modes and axle loads

9.3.3

Heavy load lattice extension (SLS)

Heavy load lattice extension 2.0 m

All axle loads specified apply to a reeved 1-sheave hook block, weight 450 kg (990 lbs).

Counterweight in t

The axle loads are applicable for all approved tyres; GMK4100L-1.

telescope status telescopic section I-II-III-IV-V-VI in %

à Betriebsanleitung

Main boom Lattice Superstrucangle extension ture in ° inclination position 1) in °

Maximum axle load 2) in t front

rear

0-0-0-0-0-0

15 - 59

0 - 40

front

15.5

12.5

0-0-0-0-0-0

55 - 59

0 - 40

rear

8.5

15.0

0-0-0-0-0-0

5 - 59

0 - 40

front

14.5

15.5

0-0-0-0-0-0

45 - 59

0 - 40

rear

10.5

16.5

0-0-0-0-0-0

5 - 59

0 - 40

front

14.0

16.5

0-0-0-0-0-0

45 - 59

0 - 40

rear

11.0

16.5

0-0-0-0-0-0

5 - 59

0 - 40

front

14.0

17.0

0-0-0-0-0-0

40 - 59

0 - 40

rear

11.5

17.0

0-0-0-0-0-0

5 - 50

0 - 40

front

13.5

17.0

0-0-0-0-0-0

35 - 59

0 - 40

rear

12.5

18.0

0-0-0-0-0-0

5 - 45

0 - 40

front

13.0

17.5

0-0-0-0-0-0

35 - 59

0 - 40

rear

13.0

18.0

0-0-0-0-0-0

5 - 40

0 - 40

front

12.5

18.5

0-0-0-0-0-0

25 - 59

0 - 40

rear

14.0

19.0

0-0-0-0-0-0

5 - 35

0 - 40

front

12.0

19.0

0-0-0-0-0-0

20 - 59

0 - 40

rear

14.5

19.0

0-0-0-0-0-0

5 - 30

0 - 40

front

11.5

20.0

0-0-0-0-0-0

5 - 59

0 - 40

rear

15.5

20.0

0-0-0-0-0-0

5 - 15

0 - 40

front

10.5

20.5

0-0-0-0-0-0

5 - 59

0 - 40

rear

16.5

20.0

50-0-0-0-0-0

5 - 45

0 - 40

front

15.0

21.5

0-0-0-0-0-0

5 - 59

0 - 40

rear

17.5

20.0

0.8

4.5

5.7

6.7

8.5

9.7

11.6

13.1

14.9

19.9

9 - 12

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Lattice extension operating manual GMK 4100L-1

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17.4

Driving with a rigged crane 9.3 Permissible rigging modes and axle loads

Counterweight in t

telescope status telescopic section I-II-III-IV-V-VI in %

Main boom Lattice Superstrucangle extension ture in ° inclination position 1) in °

Maximum axle load 2) in t front

rear

50-0-0-0-0-0

5 - 40

0 - 40

front

15.0

22.0

0-0-0-0-0-0

5 - 59

0 - 40

rear

18.5

20.0

50-0-0-0-0-0

5 - 30

0 - 40

front

14.0

22.5

0-0-0-0-0-0

5 - 59

0 - 40

rear

19.5

20.0

50-0-0-0-0-0

5 - 25

0 - 40

front

13.5

23.5

0-0-0-0-0-0

5 - 59

0 - 40

rear

21.0

20.0

21.4

24.0

26.2

à Notes on the tables, p. 11 - 3

07.11.2018

1), 2)

Lattice extension operating manual GMK 4100L-1

3 302 730 en

9 - 13

Driving with a rigged crane 9.3 Permissible rigging modes and axle loads

9.3.4

Auxiliary single-sheave boom top • When driving with a rigged auxiliary single-sheave boom top, proceed in

à Betriebsanleitung

07.11.2018

the same way as for driving with a rigged truck crane; GMK 4100L-1.

9 - 14

3 302 730 en

Lattice extension operating manual GMK 4100L-1

Driving with a rigged crane 9.4 Before driving

9.4

Before driving • Before driving you must sequentially perform all steps described here, while also observing all specifications and safety instructions in the corresponding sections of the operating manual provided; Betriebsanleitung GMK 4100L-1.

à

– Secure the superstructure against slewing – Checking tyre pressure and wind speed – Setting the truck crane on the wheels – Select the driving direction and switch on the separate steering (transmission/connections)

9.5

While driving The same specifications, restrictions and safety instructions applying to driving a rigged truck crane without a rigged lattice extension also apply to driving a rigged truck crane with a rigged lattice extension.

For safety reasons, the outrigger beams should remain extended corresponding to the space available. The outrigger pads must not touch the ground while the crane is being driven.

• Observe all specifications and safety instructions in the corresponding sections of the operating manual provided; 1.

9.6

à Betriebsanleitung GMK 4100L-

After driving • After driving you must perform the same steps as those required after driving a rigged truck crane without a rigged lattice extension. When doing this you must also observe all specifications and safety instructions in the corresponding sections of the operating manual provided; Betriebsanleitung GMK 4100L-1.

07.11.2018

à

Lattice extension operating manual GMK 4100L-1

3 302 730 en

9 - 15

Driving with a rigged crane 9.6 After driving

07.11.2018

Blank page

9 - 16

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Lattice extension operating manual GMK 4100L-1

Index

10

Index The index has the following structure: The names of the parts or assemblies you are searching for are listed in alphabetical sequence on the far left at the beginning of the line. The following are indented under these terms: – Activities (e.g. placing/removing the hoist rope) or – Subcategories (e.g. transport) or – Subcategories related to activities (for example, swinging the lattice extension).

07.11.2018

H

The first search word is always a noun and is followed by an operation or a sub-term.

Lattice extension operating manual GMK 4100L-1

3 302 730 en

10 - 1

Index

07.11.2018

Blank page

10 - 2

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Lattice extension operating manual GMK 4100L-1

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Index

A

Auxiliary single-sheave boom top Fitting/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 Installing/removing a folded up auxiliary single-sheave boom top . . . . . . . . . 7 - 9 Installing/removing the camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 16 Installing/removing the lifting limit switch and anemometer . . . . . . . . . . . . . 7 - 13 Maintenance Description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 22 Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21 Moving into the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6 Moving into the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3 Operation Procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . 7 - 19 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17 Possible reeving methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 12 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 Transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2 Transport dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2

B

Basic safety instructions ............................................................................................. 2 - 1 Boom extension ........................................................................................................... 5 - 1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 Attaching/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20 CHECKLIST Installing the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6 Removing the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9 Checklists for rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5 Electrical connections - section 3/main boom . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15 Electrical connections - section 3/swing-away lattice . . . . . . . . . . . . . . . . . . . . 5 - 17 Folding the deflection sheave out/in - section 3 . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2 Installing/removing section 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 14 Installing/removing the swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 19 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 27 Description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 28 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 23 Derricking/telescoping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 25 Procedure if the permissible wind speed is exceeded . . . . . . . . . . . . . . . . 5 - 26 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 23 Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1 Possible reeving methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 Transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4 Transport dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4

D

Driving with a rigged crane ........................................................................................ 9 - 1 After driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15 Before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15

Lattice extension operating manual GMK 4100L-1

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10 - 3

Index

Permissible rigging modes and axle loads Auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 14 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 3 Swing-away lattice 1.7 + 14.3 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 6 Swing-away lattice 1.7 + 7.7 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 4 Swing-away lattice 2.0 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 12 Swing-away lattice 9.7 + 14.3 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 Swing-away lattice 9.7 + 7.7 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 8 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 1 While driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 15 Driving with a rigged truck crane Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 2

Heavy load lattice extension 2.0 m ............................................................................ 6 - 1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1 Checklists for rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7 Derricking, telescoping the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 39 Establishing the electrical connection to the main boom . . . . . . . . . . . . . . . . 6 - 30 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2 Installing/removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 23 Installing/removing the camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 35 Installing/removing the lifting limit switch and anemometer . . . . . . . . . . . . . 6 - 34 Maintenance Description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 42 Maintenance plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 41 Moving into the working position/transport position . . . . . . . . . . . . . . . . . . . . 6 - 26 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 37 Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1 Positioning/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 31 Possible reeving methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 32 Procedure if the permissible wind speed is exceeded . . . . . . . . . . . . . . . . . . . 6 - 39 Removing from the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 15 Rigging in the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11, 6 - 21 Rigging in the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 8, 6 - 17 Setting the angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 36 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 37 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3 Transport condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 Transport dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 Unrigging from the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 Hoist rope Possible reeving methods on the auxiliary single-sheave boom top . . . . . . . 7 - 12 Possible reeving methods on the heavy load lattice extension . . . . . . . . . . . . 6 - 32 Possible reevings on the swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 88

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Load turning, see "Turning loads over" .................................................................... 8 - 1

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Index

O

Operating elements ..................................................................................................... 3 - 1 In the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7 On the lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 Other operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9 RCL control unit with MAXbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8 Operating Manual Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Operating manual Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Safety instructions for working with lattice extensions . . . . . . . . . . . . . . . . . . . 2 - 2 Terms used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2

P

Possible reeving methods On the auxiliary single-sheave boom top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 12 On the boom extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21 On the heavy load lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 32 Possible reevings on the swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 88

R

Rigging hook ................................................................................................................ 3 - 9

S

Safety instructions ....................................................................................................... 2 - 1 For working with lattice extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2 Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Swing-away lattice Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 Attaching/removing the hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 86 Checklist Installing in transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 21 Installing in working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17 Removing from the transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27 Removing from the working position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24 Rigging the swing-away lattice in the operating position . . . . . . 4 - 30, 4 - 35 Rigging the swing-away lattice in the transport position . . . . . . . 4 - 39, 4 - 44 Subsequent necessary rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 48 Subsequent necessary unrigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 50 Checklists for rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15 Derricking the main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 98 Description of the rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 53 Establishing/disconnecting electrical connections . . . . . . . . . . . . . . . . . . . . . . 4 - 77 Establishing/disconnecting the electrical connection between section 1/section 2 .

4 - 65 Establishing/separating the slewing connection . . . . . . . . . . . . . . . . . . . . . . . . 4 - 67

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Finding and eliminating malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 113 Troubleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 113 Folding deflection sheaves out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 75 Folding the fall-back guard out/in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 60 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3 Installing/removing the air traffic control light . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 91 Installing/removing the anemometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 91 Installing/removing the camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 93 Installing/removing the lifting limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 89 Main boom operation when the swing-away lattice is folded/rigged . . . . . . 4 - 101 Main boom operation with a folded lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 95 Main boom operation with a folded swing-away lattice Necessary rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 95 Maintenance Description of maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 105 Maintenance plan M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 103 Maintenance plan M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 103 Maintenance plan M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 103 Operation with the swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 97 Operations planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 Overview of the checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15 Permissible combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1 Procedure if permissible wind speeds are exceeded . . . . . . . . . . . . . . . . . . . 4 - 100 Rigging work Swinging Swinging section 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 83 When rigging into the transport position . . . . . . . . . . . . . . . . . . . . . . . . 4 - 82 When rigging into the working position . . . . . . . . . . . . . . . . . . . . . . . . 4 - 81 Section1/section2 – Establishing/separating the right-hand connection . . . . 4 - 61 Securing the sections with a rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 53 Setting the angle - with an auxiliary crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 68 Setting the angle - without an auxiliary crane . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 69 Setting the RCL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 97 Slinging points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 4 Telescoping with a rigged swing-away lattice . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 99 Transport condition, folded up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11 Transport condition, removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7 Transport dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6

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